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Improving Bulk
Solids Handling page 43
Fluid Sealing
Chlor-Alkali Production Facts at Your Fingertips:
Air Separation
Performance Materials
Focus on Mobile
Interpreting Spectroscopy Data Engineering
Chem Show Preview Applications
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Cover Story
43 Part 1 Feeder Design for Solids Handling Processes
involving the movement of bulk solid materials require careful consideration
of the feeder equipment design, including how the feeders work with various
bins and hoppers
51 Part 2 Choosing Agglomeration Processes
A products intended use often dictates what type of
agglomeration equipment should be used. Presented here is
a discussion of the main types of equipment and methods for
forming agglomerates
In the News
7 Chementator
Liquid metal membranes improve on Pd membrane for
separating hydrogen; A mag-drive pump that handles suspended
solids; Making graphene from graphite without oxidation;
Accelerated decomposition of halogenated compounds;
Commercial launch for MOF-based gas storage; and more
13 Business News
AkzoNobel opens paint manufacturing facility in the U.K.; Solvay to begin 43
PEKK production in the U.S.; Ineos announces plans to construct VAM plant
in Europe; Air Products forms JV with LuAn Clean Energy in China; Aveva to
merge with Schneider Electric; and more
16 Newsfront The Greening of Chlor-Alkali Production
Environmental regulations and high energy costs are driving technology advances
to make chlor-alkali plants cleaner and more efficient
22 Newsfront New Performance Materials Solve 51
Industrial Challenges From additives to polymers to coatings to 3-D
printables, new materials improve performance
86 32 New Products
Rapid online analysis of phosphorous content; A wall-mountable meter for
particle measurement; A very compact, standalone PLC; A new range of filter
bags for industrial applications; This pressure switch is freely configurable with
scalable outputs; and more
92 Show Preview Chem Show 2017
The 2017 Chem Show will take place in New York City from Oct. 31 to Nov. 2. A
28
selected group of products on display at the show is presented here
Departments
5 Editors Page Getting ready
Recent events have brought the need for disaster preparedness to the forefront
of our attention
100 Economic Indicators
32
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69 Special Advertising Section: CPI Product Review
84 Sealing Special Section
85 Hot Products
96 Product Showcase
97 Classified
98 Reader Service
99 Ad Index
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2017 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
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FCCU
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Editor s Page
EDITORS ART & DESIGN
Getting ready
DOROTHY LOZOWSKI ROB HUDGINS
M
Editorial Director Graphic Designer y local municipality recently mailed out a brochure titled
rhudgins@accessintel.com
dlozowski@chemengonline.com Are you ready?. It is a guide booklet about what to do
GERALD ONDREY (FRANKFURT) PRODUCTION in case of a nuclear emergency. I live close to a nuclear
Senior Editor
gondrey@chemengonline.com SOPHIE CHAN-WOOD power plant. The brochure describes radiation, how to
Production Manager
schan-wood@accessintel.com shelter-in-place, where evacuation routes are and what to bring with
SCOTT JENKINS
Senior Editor INFORMATION you in case of an evacuation. It also contains tips on what to do to
sjenkins@chemengonline.com SERVICES get ready before an actual emergency. Suggestions include having
MARY PAGE BAILEY CHARLES SANDS potassium iodide on-hand (KI is said to block radioactive iodine from
Associate Editor Director of Digital Development
mbailey@chemengonline.com csands@accessintel.com entering the thyroid gland), making sure your pets have identifying
GROUP PUBLISHER CONTRIBUTING EDITORS
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SUZANNE A. SHELLEY
that require fast reactions is very real, as has been brought to the
MATTHEW GRANT
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AUDIENCE CHARLES BUTCHER (U.K.) Getting ready, as best as possible, before an emergency is good ad-
cbutcher@chemengonline.com
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SARAH GARWOOD PAUL S. GRAD (AUSTRALIA)
Audience Marketing Director pgrad@chemengonline.com
sgarwood@accessintel.com When disaster strikes
JESSICA GRIER
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In late August and early September, Hurricanes Harvey and Irma dev-
Marketing Manager
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JOHN CARSON JOHN HOLLMANN ing caused temperature-sensitive organic peroxides to decompose
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ITS
IMPOSSIBLE
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2017 Emerson Electric Co.
Chementator
Liquid metal membranes improve on Pd
membranes for separating hydrogen Edited by:
Gerald Ondrey
A
membrane Sandwiched liquid metal He Nonporous silicon-
carbide tube
of liquid gal- membrane (SLiMM) Shell H2 DPC MONOMER
lium (Ga) sand-
As part of an NEDO project,
wiched between Liquid gallium Asahi Kasei Corp. (Tokyo,
two porous silicon car- Hydrogen
helium
+
layer
Japan; www.asahi-kasei.
bide supports offers a Hydrogen
atom co.jp) verified a newly de-
pathway to improve the veloped process for di-
currently available mem- phenyl carbonate (DPC), a
branes of solid palladium H2 monomer used to produce
(Pd) metal for separating He H2 polycarbonate (PC) at its
hydrogen after the steam Mizushima Works (Kura-
reforming of methane. shiki, Okayama). The stabil-
ity and operability of the pro-
Pd metal is effective
cess was confirmed through
at allowing hydrogen over 1,000 h of continuous
to pass while exclud- Porous silicon- Liquid gallium operation. Compared to the
ing other species, such carbide support layer
conventional process, the
Worcester Polytechnic Institute
as CO2 and CO, but Pd new process successfully re-
has limitations. Pd is costly and so must be carried out, liquid Ga achieves the same duces energy consumption
be spread into thin layers, which can crack dissociation of H2. The hydrogen atoms and CO2 emissions while
easily, allowing all gases through. Also, Pd then hop from one interstitial site to another, using CO2 as a feedstock.
membranes are adversely affected by sulfur across the 200-m-thick Ga layer, says re- This new route to DPC
in the gas mixture. Researchers at Worces- search team leader Ravindra Datta. (Chem. Eng., April 2015,
p. 10) uses only an alcohol,
ter Polytechnic Institute (WPI; Worcester, The gallium membranes offer several key
phenol and CO2 as feed-
Mass.; www.wpi.edu) have developed a advantages over Pd membranes. First, gal- stocks, and therefore in-
separation membrane that uses liquid Ga liums cost is an order of magnitude lower creases the flexibility of the
instead of solid Pd to separate hydrogen. than Pd, and the metal is non-toxic. Also, as companys phosgene-free
The team has successfully demonstrated Datta explains, the liquid membrane is self- PC process (Chem. Eng.,
the system, known as a SLiMM (sandwiched healing, so it can spontaneously repair any December 2005, p. 16),
liquid metal membrane), to separate H2 from cracks or defects. Further, he says there is which uses ethylene oxide
gas mixtures of helium (see diagram). more interstitial space in a liquid metal than (EO) as feedstock.
When H2 contacts a Pd membrane, it dis- a solid, so the hydrogen atoms can diffuse
sociates into hydrogen atoms, which diffuse through the material more easily. LANDFILL LEACHATE
through the membrane and recombine on The WPI team plans to test its SLiMMs OriginClear Inc. (Los Ange-
the other side. At the elevated temperatures with real-world synthesis gas mixtures from les, Calif.; www.originclear.
at which steam methane reforming would steam-methane reforming. com) recently announced
its first order to retrofit an
existing treatment site for
landfill leachate water with
Getting more value from recycled polystyrene the companys Electro-Wa-
ter Separation (EWS) and
A
lthough polystyrene has been to produce materials for construction ap- Advanced Oxidation (AOx)
adopted into a large number of plications, such as insulation. The process technologies. Rainfall gener-
end products, it remains one of chemically transforms polystyrene waste ates runoff from landfills that
the least-recycled plastic waste streams by selectively lowering the molecu- must be treated because
streams an estimated 95% of polysty- lar weight (chain length), creating a homo- it is highly contaminated
rene materials are discarded after a single geneous product. According to GreenMan- with debris and microbes.
This landfill leachate water
use. Employing a proprietary thermo-cat- tra, this is the first technology of its kind
is difficult to treat because
alytic process, GreenMantra Technologies to target and produce styrenic polymer it quickly overwhelms filters
(Brantford, Ont., Canada; www.greenman- products from waste polystyrene on a large and membranes, the com-
tra.ca) is planning to build a demonstration scale. Existing end-of-life options for poly- pany says. OriginClear will
plant that will recycle 1,000 metric tons per styrene include energy production via incin- install its EWS:AOx system
year (m.t./yr) of polystyrene waste into sal- eration, or processes that produce lower- at an existing commercial-
able end products. Construction for the value products, such as densified, ridged scale treatment facility for
plant is slated to begin in 2018. polystyrene plastic or styrene monomer. landfill leachate in Negeri
The styrenic polymer products result- Waste polystyrene is the primary raw ma- Sembilan, Malaysia to in-
ing from GreenMantras recycling process terial for GreenMantras process, and the crease the plants treatment
capacity from 26,000 gal/d
have been validated for use in ink applica- company says is has achieved 90% yield
to 100,000 gal/d. EWS uses
tions, and initial investigations also indicate of its target polymer products with minimal
that the technology could be augmented production of byproducts. (Continues on p. 8)
I
n critical pumping applications in-
rate from the water. The elec-
volving toxic or expensive prod-
tric pulses generate reactive
oxygen species that can be
ucts, the use of double mechanical
used to disinfect water with- seals or external flushing fluids can
out chemicals. OriginClear has lead to product contamination or leak-
developed a reactor module age, as well as additional costs for in-
specifically for AOx (for more stallation and monitoring. Although
details, see Chem. Eng., Au- hermetically-sealed pumps, such as
gust 2013, p. 11). magnetically-driven (mag-drive) pumps
can prevent such problems, mag-drive
UTILIZING FOOD WASTE pumps run into problems when pump-
Researchers at Cornell Uni- ing fluids with suspended solids, says
versity (Ithaca, N.Y.; www.cor- Mario Monza, export sales manager at
nell.edu) recently published CDR Pompe S.r.l. (Bollate, Italy; www.
a study investigating the use cdrpompe.com). CDR Pompe has re-
of hydrothermal liquefaction
solved this drawback, with its newly de-
to enhance the conversion of
food waste into biomethane.
veloped XTN-XTS pump series, which
Hydrothermal liquefaction is will formally be launched at next years
a thermochemical conversion Achema trade fair.
of biomass into liquid fuels The XTN-XTS series features a pat-
using a hot, pressurized water ent-pending, dynamic-shaft design with In a field application at a pharmaceutical
environment. The process an open style impeller, which allows solids to manufacturer, the pump has operated suc-
also results in a carbon-rich circulate inside the pump, explains Monza. All cessfully for over one year, says Monza. The
aqueous phase, which can passages between static and rotating parts XTN-XTS prototype was used for pumping
be converted to biomethane are designed using strategically located organic solvents with a fluctuating solids
by anaerobic digestion. The
pressure differences inside the pump to concentration of between 10 and 30%, with
combination of the two pro-
cesses speeds the conversion
avoid resistance to circulation and accumu- organic solids size up to 1 mm.
of waste to energy, compared lation of solid particles (diagram). A gener- The company is now ready to commercial-
to directly subjecting the bio- ous axial canal on the pump shaft eliminates ize the pump series, and plans to offer mod-
mass to anaerobic digestion axial-thrust forces, and allows for the circu- els in 316 stainless steel or lined with PFA
alone, the researchers say. lation of solids. Finally, diamond-coated SiC (perfluoroalkoxy alkanes). Pumping capaci-
Production of biomethane bushes are used to protect from dry-running ties range from 10 to 60 m3/h with heads
directly from food waste in an and increase abrasion resistance, he says. up to 50 m.
anaerobic digester takes days,
while production of biogas
from the aqueous phase of hy-
drothermal products takes only Extracting lithium without roasting
minutes, the team says.
L
Food waste represents a ithium Australia NL (Perth, Western pregnant liquor solution to 4 to precipitate
large component of landfilled Australia; lithium-au.com) has gen- aluminum and fluoride from solution, with a
municipal waste in the U.S., erated 99.8% (battery-grade) lithium subsequent softening step to remove excess
and 30% of food produced carbonate from lithium-bearing sili- CaSO4, followed by evaporation and precipi-
is ultimately wasted, mak- cates, such as spodumene, using its Sileach tation of Li2CO3. The addition of halogens,
ing food waste a valuable re- process a hydrometallurgical process that such as fluoride, is essential to the operation
source and an opportunity to does not require an energy-intensive roast- of Sileach. The halogens attack the chemical
reduce carbon footprint. ing step. The company says Sileach has the bonds in the silicate mineral, causing all met-
ability to process contaminated spodumene als to go into solution.
GAS STORAGE concentrates and allows the recovery of Lithium Australia has lodged an interna-
The extreme toxicity of some components other than lithium as byprod- tional patent application for Sileach. ANSTO
gases, such as arsine, phos- ucts, including silicon and aluminum. Minerals a division of the Australian Nu-
phine and boron trifluoride,
The companys spodumene originated clear Science and Technology Organization
which are essential in the
semiconductor manufacturing
from Pilbara Minerals Ltd.s (Perth; www.pil- (Lucas Heights; www.ansto.gov.au) pro-
industry, makes their handling baraminerals.com.au) Pilgangoora lithium- vided technical assistance in the develop-
and storage very dangerous tantalum project, located 120 km from Port ment of Sileach. Performance enhancement
and costly. Rather than stor- Hedland in Western Australias Pilbara region. studies are being conducted on a bench
ing the pressurized gases Sileach involves mixing the lithium-bearing scale and improvements will be incorporated
in cylinders, the new ION-X material with a source of fluoride, such as into the ANSTO Minerals pilot plant and
product line, developed by CaF2 or HF in the presence of sulfuric acid into design specifications for a large-scale
NuMat Technologies (Skokie, at 90C for about 3 h to extract about 80% pilot plant. Further pilot testing is planned
Ill.; www.numat-tech.com) of the lithium. Li2CO3 of more than 98% on a range of minerals including lepidolite,
(Continues on p. 10) purity is obtained by raising the pH of the zinnwaldite and spodumene.
8 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
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Circle 09 on p. 98 or go to adlinks.chemengonline.com/66433-09
and distributed by Versum Ferro-coke utilization promises to reduce energy
Materials, Inc. (Tempe, Ariz.;
www.versummaterials.com), consumption in ironmaking
fills a cylinder with specialized NEDO
J
Conventional process
adsorbents made from metal- FE Steel Corp.
Sintering machine Sintered ore
organic frameworks (MOFs) (Tokyo, Japan; High-grade iron ore
for selective adsorption, stor- w w w. j f e - s t e e l .
Coke oven Coke
age and delivery of ultra-high- co.jp) plans to
High-grade coal
purity gases. build a pilot plant for New process
The MOFs were designed to using ferro coke in the
have pore sizes that perfectly Blast furnace
ironmaking process at its Binder Low-temperature tuyere
fit dopant gases, enabling high
Fukuyama area of West Low-grade iron ore High-temperature tuyere
storage capacity, even at sub-
atmospheric pressures, ex-
Japan Works, with sup- Briquetting
port from the New Energy Non-coking coal machine Pig iron
plains Ben Hernandez, CEO of Cooling tuyere
PET PRECURSOR
Researchers from the Korea
High-performance aluminum alloy
Advanced Institute of Science makes use of cerium
A
and Technology (KAIST, Dae-
jeon, South Korea; www.kaist.
newly developed aluminum-cerium extend the performance range of aluminum
edu), led by professor Sang alloy is exceptionally stable at high alloys beyond where it currently stands, ex-
Yup Lee, have developed an temperatures, and is highly corro- plains David Weiss, vice president of engineer-
efficient biocatalytic system sion-resistant, allowing its use in ing and R&D at Eck Industries. The aluminum-
to produce terephthalic acid components for advanced engines and for oxides and cerium-oxides that form on the
(TPA) from p-xylene, using other aerospace, automotive and power- alloys surface make it highly corrosion-resis-
metabolically engineered generation applications. tant. The alloys favorable corrosion properties
Escherichia coli bacteria. Co-developed by Eck Industries (Mani- have fostered its use for corrosion-resistant
TPA is an important bulk towoc, Wis.; www.eckindustries.com) and rotor blades in power generation. Generally,
chemical for manufacturing
Oak Ridge National Laboratory (ORNL; Oak most formulations of the alloy do not require
polyethylene terephthalate
(PET), which is used mainly
Ridge, Tenn.; www.ornl.gov), with fund- heat-treatment to develop mechanical proper-
to manufacture plastic bot- ing from the U.S. Dept. of Energys Critical ties, which reduces the total energy input re-
tles and clothing fibers. Cur- Materials Institute (CMI; Ames, Iowa; cmi. quirements for the alloy, Weiss says.
rently, TPA is produced from ameslab.gov), the castable Al-Ce alloy is The inclusion of the rare-earth metal ce-
the oxidation of p-xylene, being used to make cylinder heads and pis- rium is attractive to the CMI because it helps
with a typical yield of more tons for advanced gas and diesel engines, drive down the cost for less common and
than 95 mol%. The current as well as turbocharger components and more valuable rare-earth elements, such
process, however, has draw- aircraft engine parts. as neodymium and dysprosium. Most rare
backs, such as the require- The addition of cerium to molten aluminum earth deposits contain about 50% cerium.
ment for high temperatures
leads to the formation of Al11Ce3 intermetal- Using the cerium for high-performance al-
and pressures, heavy metal
catalysts, and the formation
lics that are stable at over 1,000C which loys makes rare earth deposits more eco-
of the undesirable byproduct renders the alloy stable at temperatures up nomically viable to mine, Weiss says.
4-carboxybenzaldehyde. to 500C. Typically, Ce levels of 812% are While the alloy was originally developed as
The researchers developed used to develop sufficient high-temperature a casting alloy, it is also being studied for use
a best-performing strain of strengthening. in forging and extrusion processes, as well
E. coli with an increased TPA The alloys ability to recover from damage as for additive manufacturing applications,
(Continues on p. 12) at high thermal loads over time means it can Weiss notes.
10 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Making graphene from graphite without oxidation University of Connecticut
G
raphene can be produced layers to unstack and spread out
and isolated by exfoliating in order to lower the energy of the
graphite, but existing pro- system, explains UConn profes-
cesses are difficult and ex- sor Douglas Adamson. The ex-
pensive. The most common method foliation is driven thermodynami-
involves aggressive oxidation of cally, with the graphene acting as
graphite and results in diminished a surfactant.
properties and added expense. An- Adamsons group has also de-
other approach mechanical exfo- veloped a method for making gra-
liation requires large energy input phene-polymer composites using
and produces small graphene frag- the unoxidized (pristine) graphene
ments at low yields. made in this way. The team takes
Now a research team at the Uni- advantage of the surfactant-like ize the composite materials, which
versity of Connecticut (UConn; property of graphene and generates are, in essence, porous electrodes.
Storrs; www.uconn.edu) has de- a water-in-oil emulsion containing Their first application will be as elec-
veloped a method to produce gra- the pure graphene flakes, water and trodes for capacitive deionization
phene from graphite without the one of a variety of monomers capa- (CDI)-based desalination of brack-
need for oxidation or mechanical ble of undergoing chain polymeriza- ish water. CDI removes ions by ad-
energy in a simple, thermodynami- tion. By polymerizing the monomer sorbing dissolved salts onto charged
cally driven process that has not while in the emulsion, the research- electrodes. A major challenge in CDI
been reported before. ers build an open cell foam compos- is the cost of commercial-scale CDI
The process places graphite at an ite containing a continuous network electrodes. Using the UConn teams
oil-water interface with high interfa- of graphene without requiring any stabilized graphene composites as
cial energy. If you think of graphite high-energy processes or oxidation CDI electrodes could allow CDI to
as stacked layers of graphene, plac- of the graphene. enter large-scale use, as their cost
ing the graphite material at the oil- Adamson and colleagues have to manufacture is lower than polysty-
water interface causes the graphene formed a company to commercial- rene foam, Adamson says.
Give your
productivity
the power of 7.
A
the byproduct. The researchers designed a new research partnership be- compound and making it more vulner-
two-phase (aqueous/organic) fermentation tween the Water Environment able to oxidation.
system for TPA production on a larger scale, & Reuse Foundation (WERF; This strategy known as ad-
where p-xylene was supplied in the organic Alexandria, Va.; www.werf. vanced oxidation integrated with re-
phase. Through a few optimization steps, org) and the University of Texas at duction, or AIR will employ zero-
they achieved production of 13.3 g of TPA Arlington (UTA; www.uta.edu) seeks valent iron (ZVI) conjugated with
from 8.8 g of p-xylene a yield of 97 mol%.
to tackle one of the most challenging common oxidants. According to the
and persistent water contaminants team, well-dispersed ZVI nanopar-
ANTI-SOLVENT CRYSTALLIZATION perfluorooctane sulfonate (PFOS). ticles (Fe0) chemically reduce PFOS
Wageningen University & Research (www. Current industrial methods for treat- while oxidizing and transforming into
wur.nl) and IPSS Engineering (both, Wagenin-
ing PFOS in water involve physical Fe2+ and Fe3+, at which point the Fe
gen, the Netherlands; www.ipss) have signed
a long-term cooperation agreement for the
removal via membrane separation or ions can activate added oxidants to
further development, optimization and com- adsorption process, but there are no produce hydroxyl and sulfate radicals
mercialization of the new anti-solvent crystalli- widely used chemical degradation that attack and decompose PFOS via
zation technology, tradenamed ProKris. WUR processes due to the difficulties asso- oxidation routes. The team will con-
and IPSS have been cooperating in this field in ciated with removing halogen atoms. tinue to investigate if this combina-
a number of projects since 2014. Currently, a Although halogenated compounds tion of oxidative decomposition with
project aims to build the first pilot installation are highly resistant to chemical oxida- reductive dehalogenation would be
for the ProKris technology at the WUR. tion, research published in Environ- effective in large-scale PFOS degra-
ProKris is based on the use of anti-solvents mental Engineering Science showed dation. The team believes that the
to separate and isolate valuable compo-
that introducing a preliminary chemi- AIR process could be easily scaled
nents, such as sucrose, fructose, lactose,
insulin and isosaccharinic acid from complex
cal reduction step prior to oxidation up, but that the costs to acquire large
mixtures, such as sugar beets, beet pulp, may enhance PFOS decomposition. quantities of ZVI might pose some is-
black liquor and all other sugar-containing The initial chemical reduction step sues. This research is slated for com-
feedstocks and waste streams. strips off the fluorine, weakening the pletion in the Fall of 2018.
Herbicides Minerals
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The Greening of
Chlor-Alkali Production
Environmental regulations and high energy costs are driving technology advances that make
plants cleaner and more efficient
AkzoNobel
IN BRIEF
F
or some, the production of
CLOSING THE GAP chlorine and caustic has
been considered a nasty
NEW MEMBRANES business: not only are the
OXYGEN DEPOLARIZED products dangerous if not han-
CATHODES dled properly, but the traditional,
THE MERCURY ERA
century-old chlor-alkali process
COMES TO AN END
itself the electrolysis of brine
has been carried out in hundreds
STAYING COMPETITIVE of cells that either contain mercury
(a toxic pollutant) or a diaphragm
made of asbestos (a carcinogen).
And continuously flowing through
the banks of cells are thousands
of Amperes of electrical current FIGURE 1. AkzoNobels MEB (Membraan Electrolyse Bedrijf) plant in Rot-
terdam is one of the first and largest membrane-based chlor-alkali plants in
2
(current densities of 56 kA/m ), Europe. The facility is now converting to the latest zero-gap membrane tech-
which makes the process one of nology, which will significantly increase the energy efficiency
the most energy-intensive in the chemical 3135). And more recently, the switch to
process industries (CPI). so-called zero-gap technology, in which the
Nevertheless, both Cl2 and NaOH, as well gap between the cathode and the mem-
as the byproduct H2 are extremely important brane is minimized, is pushing the efficien-
in just about all sectors of the CPI. In Europe, cies to nearly the thermodynamic optimum,
for example, over half of all chemicals pro- says Jacqueline Oonincx, director Tech-
duced rely on chlor-alkali products, with the nology Chlor-Alkali & Chloromethanes,
vast majority of Cl2 used in modern plastics, Akzo Nobel N.V. (AkzoNobel; Amsterdam;
such as polyvinylchloride (PVC), according to the Netherlands; www.akzonobel.com).
Euro Chlor (Brussels, Belgium; www.euro- The companys MEB plant in Rotterdam
chlor.org). Also, 85% of all medicines made (Figure 1), for example, is currently being
in Europe are based on chlorine, over 90% modernized to incorporate the latest zero-
of European drinking water is made safe gap membrane technology a process
for consumption using chlorine and 25% of that takes several years to carry out.
medical devices involve chlorine chemistry in
their production, says Euro Chlor. Closing the gap
Because of the tremendous need for The first fully zero-gap membrane cell
these products, and the fact that trans- was launched in 2012, when thyssenkrupp
porting huge volumes of Cl2 is impractical, Uhde Chlorine Engineers (Dortmund, Ger-
hundreds of chlor-alkali plants are running many; www.thyssenkrupp-uhde-chlorine-
throughout the world close to where the engineers.com) introduced its BM2.7v6
Cl2 is needed and will continue to be in- the sixth generation of its single-element
dispensible. What makes todays chlor-al- membrane cell. Like its predecessors, the
kali plants different from those of just a few cells have a membrane area of 2.72 m2,
decades ago, is that they are much more making it easy to upgrade existing units.
efficient than their predecessors due to The BM2.7v6 is said to have a zero gap
the introduction of bipolar membrane tech- over the entire active membrane. As a re-
nology (Chem. Eng., February 2001, pp. sult, the BM2.7v6 reduces power consump-
16 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Viega MegaPress Stainless
viega.us/mpstainless
Circle 44 on p. 98 or go to adlinks.chemengonline.com/66433-44
TABLE 1. COMPARISON OF CHLOR-ALKALI PROCESSES
co.jp) gave an overview of its latest
Units Mercury Diaphragm Membrane Membrane
process process process ODC process* ion-exchange membrane technol-
Power kWh/m.t. (Cl2) 3,2003,600 2,3002,900 2,2002,600 1,6001,700 ogy, the Aciplex-F6800 series of per-
consumption fluorosulfonic acid membranes, and
Steam demand kWh/m.t. (Cl2) 0 8001,000 200400 200400 previewed the next development, the
for 50%
caustic soda
F7001X, which will be commercial-
Total power kWh/m.t. (Cl2) 3,2003,600 3,1003,900 2,4003,000 1,8002,100 ized in 2018. The F7001X features
consumption the companys patented Ion Cluster
CO2 m.t.CO2/m.t.Cl2 1.82.0 1.752.2 1.351.7 1.01.2 Control technology, which is said to
emissions** enhance the current efficiencies by
CO2 balance % +44% +42% +26% Reference value
0.30.5% for the same cell voltage
Notes:
*Accounts for the energy demand for producing the O2 used in the oxygen depolarized cathode (ODC) process.
(CV). The F7001X has been shown to
** Assuming 565 kg of CO2 per mWh of electricity (source: Bundesumweltamt, 2009). enable cell voltages to be reduced by
Credit for table: thyssenkrupp 50 mV compared to the F6808.
tion to 2,0202,035 kWh per metric this technology, says Jeff Pan, CCO
ton (m.t.) of NaOH at 6 kA/m2, says and Overseas business director at Oxygen depolarized cathodes
the company (see Table 1 for com- Bluestar. The company is now work- Possibly the biggest quantum jump
parisons). The BM is being used in ing to further reduce the energy con- in terms of energy reductions in the
a number of commercial plants, in- sumption to below 2,020 kWh/m.t. chlor-alkali production process has
cluding several recent conversions of NaOH with its NBZ-X electrolyzer, been the introduction of the oxygen
from mercury to membrane tech- which is expected to be commercially depolarized cathode (ODC) technol-
nology, such as AkzoNobels plant available within the next two years, ogy (Figure 2). This magazine has
in Frankfurt am Main, Germany says Pan. It will be a skid-mounted been following this breakthrough
(250,000 m.t./yr of Cl2), which was plant that is easily installed, and the since it was originally developed by
completed in 2015. More recently active electrode area will be smaller Covestro AG (formerly Bayer Mate-
(October 2016), CABB AG (Pratteln, than the NBZ-2.7 II, he explains. rialScience; Leverkusen, Germany;
Switzerland; www.cabb-chemicals. www.covestro.com) and thyssen-
com) started up two electrolyzers, New membranes krupp (for more details, see Chem.
each with 131 sixth-generation, In a related effort to reduce energy Eng., May 2007, pp. 5055, and
single-element cells from thyssen- costs, new generations of ion-ex- Chem. Eng. December 2014, pp.
krupp, thereby replacing the amal- change membranes are also being 1722). This technology reduces
gam electrolysis plants. The new developed. AGC Chemicals, a di- power consumption by up to 25%,
plant increases the Cl2 capacity from vision of Asahi Glass Co. (Tokyo, and it has already been imple-
27,000 m.t./yr to 47,000 m.t./yr, Japan; www.agc-chemicals.com), mented in several industrial plants
thereby meeting the sites demands has continued its efforts to reduce worldwide since 2011, says thys-
and essentially eliminating the need electric resistance of its ion-ex- senkrupps Krude.
for Cl2 transports, says CABB. change membranes over the last 40 The company also offers ODC
We are working continuously on years. The companys current flag- technology for making Cl2 from HCl,
improving our technologies; for ex- ship product, the Flemion F-8080, a process that promises to be an
ample with new surface structures, is a cation-exchange membrane (a important way to recycle HCl gener-
membranes, materials or coatings, fluorinated carboxylic polymer) that ated in the production of methylene
says Denis Krude, CEO of thyssenk- offers extremely low resistance and diphenyl diisocyanate (MDI) and tol-
rupp Uhde Chlorine Engineers. The is said to be the preferred product by uene diisocyanate (TDI). MDI and
main target is to lower the power many users. The use of carboxylic TDI production facilities are operat-
consumption even further, under polymer helps ion-exchange mem- ing at extremely high rates due to
2,000 kWh/m.t. NaOH, he says. branes in salt electrolysis achieve the tight isocyanate markets, result-
Meanwhile, other membrane-elec- high electrical current efficiency. ing in increased availability of HCl,
trolysis suppliers are also working At Euro Chlors 10th Technol- says Krude.
to improve efficiencies of their own ogy Conference (May 1618; Berlin,
zero-gap technology. For example, in Germany), the company introduced Mercurys era comes to an end
2014, Bluestar (Beijing) Chemical Ma- the latest Flemion membranes and Although the conversion of mercury
chinery Co. (China; www.bcmc.com) said it is working on a soon-to-be cells to membrane cells can make
first commercialized its second-gen- released version, the Fx-634, which good economic sense in terms of
eration zero-gap electrolyzer technol- is more robust than the F-8080 and reducing operating costs (see Table
ogy, the Natural Circulation Bipolar F-8080A, and will enable a further re- 1), a number of mercury plants are
Zero Gap Electrolyzer (NBZ-2.7II), duction of the operating voltage by still operating around the world, es-
which has a power consumption 50 mV, the company says. pecially in Europe, where the mercury
of 2,030 kWh/m.t. of NaOH. Since Also at the the Berlin conference, cells had traditionally been the tech-
then, there are now 19 plants using Asahi Kasei Corp. (www.asahi-kasei. nology of choice. Worldwide, there
18 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Pure medical-grade bicarbonate?
Or 100,000 tonnes for food production?
What if you could do both
with one efficient solution?
The market for refined bicarbonate Its just one of countless challenges
is steadily expanding, forcing many solved by ANDRITZ SEPARATION the
producers to increase both purit y worlds leading separation specialist.
and throughput. Our latest solution? With the broadest technology portfolio
Dewatering and drying equipment for one and more than 2,000 specialists in 40
of the worlds largest production lines countries, ANDRITZ SEPARATION is a
for sodium bicarbonate, with an annual driving force in the evolution of separation
capacity of 100,000 tonnes and 15% less technologies, services, and solutions.
energy consumption than conventional Whats your biggest challenge?
technologies. Best of all, the technologys
carbon dioxide dr ying atmosphere
prevents thermal degradation to achieve
the highest levels of purity.
andritz.com/separa tion
Circle 03 on p. 98 or go to adlinks.chemengonline.com/66433-03
thyssenkrupp Uhde Chlorine Engineers
The ODC process Cathode Anode
ODC
Percolator Downcomer
02 300g NaCI/I
FIGURE 2. Shown here is the operating principle (a) of an NaCl-ODC (oxygen depolarized
cathode) cell, and an NaCl-ODC plant in operation (b)
With the adoption of from mercury-cell to the BiChlor
the EU Mercury Regula- membrane electrolyzer of Ineos
NaOH 32% 210g NaCI/I + CI2 tion in May 2017, the E.U. Technologies (London, U.K.; www.
2 NaCI + H2O + 1/2 CI2 + 2 NaOH simultaneously ratified ineos.com). Ashta says the change
the United Nations Mina- will also result in a 20% reduction in
are still 34 mercury plants with a joint mata Convention on Mercury (www. energy consumption.
production capacity of 3 million m.t./ mercuryconvention.org). This rati-
yr of Cl2, according to Euro Chlor. At fication by the E.U. Commission Staying competitive
the end of 2016, membrane tech- prompted other Member States to Since 2007, there has been a gradual
nology accounted for about 66% of act, bringing the number of ratifica- decline in European chlorine produc-
European Cl2 production capacity, tions up to the required 50 for the con- tion; the chlorine industry has not
with mercury-cells share account- vention to enter into force on August followed the general growth of the
ing for approximately 17% of the Cl2 16, 2017. The Minamata Convention chemical industry in Europe and the
production capacity, according to requires the phaseout of all mercury- rest of the world, according to Euro
Euro Chlors Industry Review 2016 cell chlor-alkali production by 2025. Chlor. The regulatory and economic
2017, published last month. The first Conference of the Parties environment in Europe continues to
In 2017, conversion of mercury (COP1) meeting was scheduled for challenge our global competitiveness,
plants to membrane processes (or September 2427, 2017 in Geneva, says executive director Dolf van Wijk.
closures of the mercury plants) will Switzerland (after this article went to He points to statistics from Cefic (The
further increase, says Euro Chlor. In press), and the The World Chlorine European Chemical Industry Coun-
2013, best available technology (BAT) Council (WCC; www.worldchlorine. cil; Brussels, Belgium; www.cefic.
conclusions under the E.U.s Indus- org) said it would be attending. Es- org) that show regulatory costs have
trial Emissions Directive implied that tablished in 1993, WCC represents doubled over the past decade, with
mercury cell technology can no longer national and regional trade associa- energy policies continuing to increase
be used in chlor-alkali units after 11 tions and their member companies, power prices due to rising taxes and
December 2017. On May 24 2017, to promote best practices and the levies, reducing our global competi-
the new E.U. regulation on mercury benefits of chlor-alkali chemistry. tiveness, he says. Europe urgently
was published (EU 2017/852). The In the U.S., the diaphragm cell is needs to improve its policy support
new regulation reinforces the phase- the dominant technology for its chlor- for the manufacturing sector to foster
out deadline of the end of 2017, and alkali sector. Of the two remaining innovation, provision of new jobs, gen-
Euro Chlor says it will continue to mercury-cell plants still operating in erate growth and supply the needs of
support the membership in identify- the U.S., one will be converted to future generations.
ing conversion and storage options. membrane technology by the end of Electricity accounts for at least
This regulation allows temporary stor- this year, and the other is expected to 50% of the chlor-alkali production
age of liquid Hg for a maximum of up close or convert by the 2025 dead- costs, says Ton Mandres, techni-
to five years, with the possibility of line of the Minamata Convention. cal director at Euro Chlor. Whereas
extension of three additional years. In 2014, Ashta Chemicals Inc. shale gas has essentially cut elec-
Meanwhile, liquid mercury must be (Ashtabula, Ohio; www.ashtachemi- tricity costs in half in North America,
converted into mercury sulfide before cals.com) announced it would be energy is a bigger challenge for the
being permanently disposed of, says investing $60 million to convert its E.U., he says.
Euro Chlor. chlor-alkali facility in Ashtabula, Ohio Gerald Ondrey
20 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Circle 36 on p. 98 or go to adlinks.chemengonline.com/66433-36
Newsfront
IN BRIEF FIGURE 1. PolyMag additives are FDA-compliant and impart metal Eriez
detectability, X-ray contrast and magnetic susceptibility when added
ADDITIVES
to plastic moldings to help prevent plastic contaminated food products
POLYMERS from reaching the consumer
COATINGS AND
ENAMELS
OTHER PERFORMANCE
MATERIALS
H
igh-performance materials are protection in marine engines and industrial
intended to make consumer applications. However, recent testing found
goods, industry and the world, in that the additive has additional properties,
general, function better. Inventive as it can prevent hydrogen embrittlement
performance materials can be found in all (or white etching cracks) the process by
categories, from additives to polymers to which metals, such as steel, become brittle
coatings and enamels to newer materials, and fracture when in contact with hydro-
such as 3-D printables. What each brings gen. This phenomenon is something that
to the table depends upon the type of ma- occurs in the structure of the metal, says
terial and the intended application, but one Nanol CEO Johan von Knorring. The met-
thing all performance materials have in allurgical process disrupts and weakens the
common is that they are constantly being structure of the metal. It occurs especially
innovated to perform better than the mate- at high loads when hydrogen atoms dif-
rials that came before. This article rounds fuse into the micro-structure of the metal.
up some of the newest materials designed This causes unpredictable metal fractures
to solve industrial challenges within several and cracking, but weve found that it can
different categories. be prevented with [the additive, also known
as] Nanol. He adds that Nanol should be
Additives viewed as a multifaceted additive that has
Many additives were developed to solve additional performance attributes, such as
problems that were plaguing industry. For viscosity improvement, friction modification
example, Nanol Technologies (Helsinki, Fin- and anti-wear properties, as well as protec-
land; www.nanol.eu) lubricant additive was tion against hydrogen embrittlement.
originally developed for fuel saving and wear The additive has mainly been used in
22 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
MilliporeSigma Stronghold Coatings
FIGURE 3. Dichtol 1532, a polymeric capillary sealer for castings and composites, impregnates micropores
FIGURE 2. Poloxamer 188 Emprove Expert poly- and hairline cracks without vacuum or pressure, forming a protective barrier to gases and liquids that is in-
mer is a surface-active non-ionic polymer used visible when cured. It penetrates deeply into the coating to prevent corrosion of the metal substrate
in cell culture media as a shear protectant and
a standard component in cell culture media for Eriezs (Erie, Pa.; www.eriez.com) to plastic moldings. Incorporating
production processes. It helps ensure lot-to-lot latest additive was developed to as- these additives into the processing
consistency and reliable performance
sist food processors that needed of items such as conveyor belts, pal-
marine engine and power-plant ap- a way to detect plastic contamina- lets, ear plugs, gaskets, totes, pens,
plications, but is finding use in new tion in food products in an effort to shovels, scoops, scraper blades
segments where hydrogen embrit- comply with standards, such as the and other plastic items used in a
tlement is an issue, such as gear Food Safety Modernization Act and food processing facility can prevent
boxes and wind-power turbines. Hazard Analysis and Risk-Based plastic-contaminated food products
Using Nanol in these applications Preventive Controls. The companys from reaching the consumer, says
will prolong service intervals, lower PolyMag additives (Figure 1) are John Collins, PolyMag business
friction, reduce energy consumption FDA-compliant and impart metal manager with Eriez, as food pro-
and decrease wear on parts, von detectability, X-ray contrast and cessors readily use these detection
Knorring says. magnetic susceptibility when added techniques to avoid having contami-
FIGURE 5. Diafilm ETC700 CVD diamond heat spreaders are the first thermal management material engi-
neered to offer electrical conductivity alongside the exceptional thermal performance of diamond
mers to advise customers about liporeSigma. Our Poloxamer 188
FIGURE 4. XuperCOAT was developed for the migration issues and regulatory Emprove Expert has a tight and
protection of molds in metals casting. The coating compliance during the product de- well-controlled molecular weight
was designed to increase the lifetime of the mold
plates or tubes and to ensure longer campaigns sign phase, preventing problems distribution, which shows superior
of first-class cast products in terms of cast shape before they occur and shortening performance compared with other
and surface quality time to market. suppliers and quality grades.
M545TF can be supplied pre- Other industries, too, are reaping
nants in their product. colored, with Elix Polymers taking the rewards of new performance
The additives are provided in pellet the responsibility for compliance polymers. For example, GreenMan-
form, allowing molders and extrud- of the pigments with food-contact tra Technologies (Brantford, Ont.,
ers to produce metal-detectable and regulations. A series of actions have Canada; www.greenmantra.ca), a
X-ray-visible plastic items used for been taken to assure no impact on clean-tech company that uses a
food contact applications. extractables and leachables. For ex- proprietary thermo-catalytic system
ample, no colorants and dyes, dis- and patented process to cost-ef-
Polymers persants or process aids are allowed fectively convert and upcycle waste
New polymers are also being cre- in recipes, unless they are approved plastic, is the first company to de-
ated for use in food-contact applica- in the base material, and only FDA/ polymerize waste polyolefin plastic
tions. For example, a new acryloni- EU pigments are used. into a synthetic wax on a commer-
trile butadiene styrene (ABS) grade Biopharmaceutical manufacturers cial scale, according to Domenic
from Elix Polymers S.L. (Tarragona, also need polymers that are devel- DiMondo, senior director, research
Spain; www.elix-polymers.com) is oped to meet regulatory require- and business development with the
for use in products that come into ments. As such, MilliporeSigma (Bil- company. The novelty of our pro-
contact with food and which also lerica, Mass.; www.emdmillipore. cess is in the non-discriminatory
require extra toughness and resis- com) offers a Poloxamer 188 poly- features of the process with regard
tance to high temperatures. While mer, a surface-active non-ionic poly- to the polyethylene or polypropylene
the company has a high level of ex- mer used in cell culture media as a plastic used. This allows us to use
perience as a supplier of ABS for shear protectant and a standard a full range of polyolefin waste plas-
medical consumer applications, it in- component in cell culture media for tics as feedstock, he says. Future
tends to transfer this competence to production processes. Millipore- commercial products will include a
food-contact applications, which are Sigmas Poloxamer 188 Emprove portfolio of styrenic polymers derived
also sensitive applications requiring a Expert polymer (Figure 2) helps en- from waste polystyrene.
high level of support and knowledge sure lot-to-lot consistency and reli- In the meantime, the technology
in regulation, says Aurelie Mannella, able performance. The product has allows the company greater control
healthcare industry manager with been cell culture tested, optimized of the polymer depolymerization
Elix Polymers. and comes with Emprove Expert and resulting product properties,
Target applications for the latest polymer dossiers to help manu- enabling them to produce drop-in
grade of ABS include kitchenware, facturers meet regulatory require- offsets or novel synthetic polymers,
products for preparation and stor- ments for risk assessment. Certain waxes and additives. Ceranovus
age of food and toys. The latest molecular weight species can have waxes, some of the newest prod-
grade has been migration tested a negative impact on cell culture ucts, are sold commercially for ap-
with different food simulants, says performance, says Andrew Bulpin, plications in asphalt modification for
Mannella. This enables Elix Poly- head of process solutions with Mil- roofing and paving, polymer pro-
24 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
cessing, masterbatch, inks, coatings and adhesives.
These products stand out from other waxes as they
can improve throughput and productivity in manufac-
turing processes such as polyvinyl chloride (PVC) ex-
trusion and plastics processing, while also helping to
reduce energy costs and equipment wear. As a modi-
fier, they can enhance the physical properties of the
end product, depending on the application, providing RECE
greater stability or performance in the field, says Di- IVE FU
Mondo. And because the waxes are produced from
post-consumer recycled plastics, they enable end ACCELL
products utilizing the wax to qualify for LEED (Leader-
ship in Energy and Environmental Design) and other
environmental credits.
Other polymer developments include the introduc-
to ALL
at Yo
SS
Facts of Chemic
al Eng
one cour Fingertip ineerings
nvenie s
nt locaarticles in
tion of Makrolon, a thermally conductive (TC) poly-
carbonate from Covestro LLC (Pittsburgh, Pa.; www.
covestro.com). The material can be used for thermal
tion.
management in a variety of components. Relevant EACH INFORMATION
applications span the electronics, automotive light- PACKED PDF ARTICLE includes
ing and light-emitting diode (LED) lighting industries. graphs, charts, tables, equations and
Makrolon TC polycarbonate can be used as a re- columns on the full chemical engineer-
placement for aluminum, a material often used in heat
sinks. Heat sinks molded using these grades provide ing processes you deal with on a daily
dissipation of the heat generated by the OEMs prod- basis. This is the tool you will come to
uct in order to maintain desired operating tempera- rely on, referring back to the information
tures and meet product performance goals. Many
existing applications are over-engineered using die
again and again with just the click of a
cast aluminum since the effect of higher conductiv- mouse.
ity is lost in certain low-convection conditions, says
Kevin Dunay, electrical industry manager, polycarbon- Facts at Your Fingertips
ates with Covestro. Unlike aluminum, the processing
temperature of Makrolon TC polycarbonate enables
Topics Include:
insert molding of components. Molding in compo-
nents allows for parts consolidation, which translates
Conservation Economics: Carbon
into reduced costs. Furthermore, the material is lighter Pricing Impacts
weight and provides enhanced design freedom when Distillation Tray Design
compared to aluminum. Burner Operating Characteristics
Coatings and enamels Measurement Guide for Replacement
High-performing coatings and enamels are also being Seals
developed to improve upon existing solutions for chal- Steam Tracer Lines and Traps
lenging industrial applications. For instance, Larry Gri-
Positive Displacement Pumps
menstein, owner of Stonghold Coatings (Franklin, Ohio;
www.strongholdone.com) says he noticed that thermal Low-Pressure Measurement for
spray coatings often failed. What I found was that the Control Valves
coatings had porosity and the sealers being sold actu- Creating Installed Gain Graphs
ally did not perform well in service, he says. I found a
special resin and ran some tests and it worked better
Aboveground and Underground
than anything in the current market. Storage Tanks
He adds that following some modifications in formula-
tion to meet safety requirements, the resulting product,
Dichtol, became a material used to seal thermal-spray Receive full access today
coatings. I was approached by automotive and pump by visiting
companies to use the sealer on cast aluminum parts.
These parts had been sealed in vacuum pressure tanks,
www.chemengonline.com/
but there were still a small percentage of failures, and magazine/facts-at-your-fingertips
some of the parts were so expensive that a small per- 24670
centage of failures became a major cost problem. Com-
www.vega.com/radar
Circle 43 on p. 98 or go to adlinks.chemengonline.com/66433-43
New Products
Endress+ Hauser Rapid online analysis of carbon monoxide, nitrogen dioxide,
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The Liquiline CA80TP phospho- data file as other connected sensors.
rus analyzer (photo) is designed for These monitors measure particles
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CA80TP measures phosphorus in automation of the DeltaV distributed
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with the option for additional outputs. less reliant on large-scale automa-
Samples are drawn from the process tion. The next-generation controller
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A precise sample volume is digested parts of the life sciences, oil-and-gas,
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cise and reproducible results from ex- fit-for-purpose DeltaV PK controller
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operation. Endress + Hauser Inc., DCS in a larger plant. Emerson
Greenwood, Ind. Automation Solutions, St. Louis, Mo.
www.us.endress.com www.emerson.com
www.steelbeltsystems.com
Coval
T
he components of air (Table 1), uniform electric
Oxygen (O2) 20.95 90.2 (183) 32.00
especially nitrogen (N2) and ox- fields in their void
Argon (Ar) 0.93 84.2 (186) 39.94
ygen (O2), are critical for many spaces. These dif- Carbon dioxide (CO2) 0.040 194.7 (78.5) 44.01
modern industrial processes. Primary ferences can be Neon (Ne) 0.0018 27.2 (246) 20.18
metals production, chemical manu- capitalized upon to Helium (He) 0.0005 4.2 (269) 4.00
facturing, gasification processes, preferentially ad- Krypton (Kr) 0.0001 119.8 (153.4) 83.8
clay, glass and concrete production, sorb N2, because Hydrogen (H2) 0.00005 20.3 (252.9) 2.02
welding and other processes depend N2 molecules are Xenon (Xe) 8.7 106 165.1 (108.1) 131.29
on O2 from air, while the chemical, more strongly adsorbed than O2 mol- include air compression, air-cooling
petroleum-refining and electronics ecules or Ar atoms. The zeolite ad- and purification, heat exchange,
industries utilize N2 for its inert prop- sorbents are paired with a pressure- refrigeration, internal product com-
erties. In addition, liquid N2 is used swing system, whereby pressurized pression and rectification (counter-
for cryogenic grinding, freeze-drying, air enters a vessel containing the current distillation, where the separa-
cryogenic storage of biological ma- adsorbent. N2 is adsorbed preferen- tion of components occurs).
terials, food freezing and other ap- tially and an O2-rich effluent stream An air-separation unit (ASU) using
plications. Argon (Ar) is used as an is produced until the bed has been a conventional, multi-column cryo-
inert material in welding, steelmak- saturated with N2. When saturation genic distillation process can pro-
ing, heat-treating and electronics is reached, the feed air is routed to duce O2 from compressed air at high
manufacturing. This one-page refer- another vessel and the regeneration recoveries and purities. The most
ence discusses the main methods of the first bed begins. Regeneration common design is a double-column
by which these common industrial is achieved by reducing the pressure system with an adjacent Ar unit.
gases can be derived from air. in the bed, which reduces the equi- To start the separation process, a
librium N2-holding capacity of the ad- large quantity of incoming air needs to
Air separation approaches sorbent and N2 is released. be liquefied. This is accomplished by
Separation of air into its constituent Membrane systems. Gas separa- cooling the air by decreasing its tem-
parts for industrial use can be divided tion processes using polymeric or perature and manipulating the pres-
into two main categories: cryogenic ceramic membranes are based on sure until condensation begins.
air separation and non-cryogenic differences in the rates at which O2 The first air-separation process was
processes. Cryogenic air separation and N2 diffuse through a membrane developed by Carl von Linde. Started
processes produce N2, O2 and Ar as that separates high- and low-pres- up in 1902, it separated O2 from air,
either gases or liquids by employing sure process streams. Membrane and was eventually developed into the
low-temperature distillation to sepa- air-separation systems are less en- double-column mechanism in 1910 to
rate the fluids. Cryogenic separation ergy-intensive than cryogenic sepa- allow the production of both O2 and
processes are most commonly used ration, but are generally more limited N2 simultaneously. The ability to ex-
when high-purity products and high in performance. Due to O2s smaller tract Ar was developed in 1913.
production rates are required. Non- molecular size, most membrane ma- The energy needed for the very
cryogenic processes for air separation terials are more permeable to O2 than low temperatures accounts for most
include the use of selective adsorption to N2. Membrane systems are usu- of the cost of production, so the ef-
to separate air components, and dif- ally limited to the production of O2- ficiency of the compression and
ferential permeation through mem- enriched air (2550% O2, rather than heat exchange are of great interest.
branes. These techniques use differ- 21 vol.% in regular air). While ASUs require high initial capital
ences in molecular structure, size and costs, they can realize relatively high
mass to separate air components. Cryogenic separation yields and can obtain large volumes
Non-cryogenic processes are carried Cryogenic air separation is currently of high-purity gases or liquids.
out at near-ambient temperatures, and the most efficient and cost-effective
are most often used in cases when technology for producing large quan- Further reading
high-purity gases and liquid products tities of O2, N2 and Ar as either gas- Vinson, D.R., Air Separation Control Technology, Computers
and Chemical Engineering, vol. 30, pp. 1,4361,446,
are not needed and when production eous or liquid products. By taking ad- 2006.
volumes are relatively small. vantage of boiling-point differences of Smith, A.R. and Klosek, J., A review of air separation
the species at very low temperatures technologies and their integration with energy conver-
Non-cryogenic air separation (see Table), a distillation column can sion processes, Fuel Processing Technology, vol. 70,
pp. 115134, 2001.
The following describes two of the be used to separate them. Alekseev, A., Basics of Low-Temperature Refrigeration,
main types of non-cryogenic air sepa- There are five major unit operations Linde AG, https://cds.cern.ch/record/1974048/files/
ration methods. required to cryogenically separate air arXiv:1501.07392.
Adsorption. Zeolites (highly porous into useful products. Key steps of Easterbrook, N., Boland T. and Farese, D., Extremely
Low-Temperature Systems, Chem. Eng., August 2015,
aluminosilicate materials) have non- the cryogenic air distillation process pp. 3844.
PROCESSING
TECHNOLOGY
SINCE 1915
DESIGNED FOR PROCESS ENGINEERS, PRODUCTION & PLANT PERSONNEL, EXECUTIVES AND R&D
For over 100 years, the Chem Show continues to connect leading manufacturers of equipment, systems and
services for the CPI with tens of thousands of professionals from every segment of the process industries.
Circle 25 on p. 98 or go to adlinks.chemengonline.com/66433-25
Technology Profile
Vinyl Acetate from Acetic Acid and Ethylene
By Intratec Solutions Ethylene, acetic Vapor-phase Vapor-phase Acetylene,
process process
V
acid, oxygen acetic acid
inyl acetate (vinyl acetate
monomer; VAM) is an impor-
Vinyl acetate
tant vinyl ester, primarily used monomer
in the production of polymers
and copolymers for coatings, paints Acetic anhydride, Addition reaction,
Methyl acetate,
Carbonylation hydrogen, carbon
and sealants, as well as for binders acetaldehyde decomposition monoxide
and in textile and paper processing.
n Raw material n Pathway n Main product
The process FIGURE 2. Several pathways are possible for producing vinyl acetate monomer
The following paragraphs describe a is routed to the crude VAM tank, acetate product with 99.9 wt.% from
typical vapor-phase oxidation process while gases from the scrubber are the overheads.
for VAM production from acetic acid recycled to the reaction. A portion of
and ethylene. Figure 1 presents a sim- these gases is washed with water to VAM production pathways
plified flow diagram of the process. remove residual acetic acid, which is VAM commercial production is most-
Reaction. Make-up and recycled also directed to the crude VAM tank. ly based on the reaction of ethylene
acetic acid pass through a vaporizer, After the water wash, the gases are with acetic acid and oxygen, but other
along with fresh and recycled ethyl- directed to an absorption column, for pathways are possible (Figure 2).
ene. The feed stream, containing ex- CO2 removal by a potassium carbon-
cess of ethylene over acetic acid, is ate solution. Economic performance
mixed with oxygen, preheated and VAM purification. In the azeotropic The total operating cost (raw materi-
fed to multi-tube reactors. The reac- column, a VAM-water mixture is als, utilities, fixed costs and deprecia-
tion occurs over palladium and gold distilled from the column overhead tion costs) estimated to produce vinyl
catalysts. Heat is removed by evapo- and fed to a decanter, along with acetate was about $1,100 per ton of
rative cooling on the reactors shell. the aqueous phase separated in the VAM in the third quarter of 2013. The
At the end of this stage, 810 wt.% pre-dehydration step. Here, an or- analysis was based on a plant with
of ethylene and 1535 wt.% of ace- ganic phase containing VAM is sepa- capacity to produce 350,000 metric
tic acid are converted to VAM. Water, rated and directed to the light-ends tons per year of VAM.
CO2 and small quantities of ethyl ac- column, while an aqueous phase is This column is based on Vinyl Ac-
etate, ethylidene diacetate, and glycol routed to the wastewater column. etate from Acetic Acid and Ethylene
acetates are the main byproducts. Ethyl acetate is withdrawn as a side Cost Analysis, a report published
VAM separation. The reactor ef- stream and discharged, and acetic by Intratec. It can be found at: www.
fluent is cooled and fed to the pre- acid from the column bottom is re- intratec.us/analysis/vinyl-acetate-pro-
dehydration column, where a crude cycled to the vaporizer. duction-cost. n
VAM stream is withdrawn from the The purpose of the light-ends col- Edited by Scott Jenkins
bottom and stored. The overhead umn is to strip off acetaldehyde and
stream is separated into an organic other volatile materials from the crude Editors note: The content for this column is supplied by In-
tratec Solutions LLC (Houston; www.intratec.us) and edited by
phase, which is recycled to the col- vinyl acetate, while the wastewater Chemical Engineering. The analyses and models presented
umn, and an aqueous phase, which is column separates residual VAM from are prepared on the basis of publicly available and non-
directed to a decanter downstream. wastewater. Finally, residual acetic confidential information. The content represents the opinions
of Intratec only. More information about the methodology for
Uncondensed gases are washed by acid and heavy-ends are removed in preparing analysis can be found, along with terms of use, at
acetic acid, and the solution formed the pure VAM column, yielding a vinyl www.intratec.us/che.
Carbon dioxide
1. Vaporizer
2. Oxidation reactor
5 6 7 3. Predehydration column
4. Crude VAM tank
Light ends to waste 5. Scrubber
6. Water wash
Fresh Vinyl 7. CO2 removal
ethylene acetate 8. Azeotropic column
9. Wastewater column
Fresh 1 10. Light-ends column
acetic 11. Pure VAM column
acid 2
Ethyl 12. Steam boiler
3 ST 12
acetate 13. Cooling tower
4 10 11 CW 13
Oxygen ST Steam
8 9 CW Cooling water
Wastewater
FIGURE 1. This diagram shows a typical vapor-phase oxidation process for vinyl acetate production
Solids Handling
Processes involving the movement of bulk solid materials require careful consideration of the
feeder equipment design, including how the feeders work with various bins and hoppers
Joe Marinelli and
T
he importance of feeder de-
Scott Miller
sign in maintaining reliable
Solids Handling
material flow in solids han-
Technologies Inc.
dling processes can easily
Arching Ratholing
be underappreciated and underes-
timated, but ignoring the feeder will IN BRIEF
likely result in costly and disastrous
outcomes. Feeders are designed FLOW PROBLEMS
to control solids flow, but they also FLOW PATTERNS
need to work well with the bin, hop-
HOPPER SHAPES:
per or silo system associated with WEDGE VERSUS
the process. Engineers can expend CONICAL
great effort and resources to evalu-
ate a materials flow properties, VOLUMETRIC FEEDER
design the best bin for those prop- TYPES
erties and spend signficant funds FIGURE 1. Arching and ratholing can result in no-flow conditions for a
solids handling process GRAVIMETRIC FEEDER
on liners or steep hoppers, only to TYPES
have all the money and effort wasted by an a rathole (Figure 1). If an arch forms, consider
improperly designed feeder. that this arch is strong enough to support the
The bin and feeder must work together to entire contents of the bin or silo and stop the
ensure uninterrupted flow from the bin. To fos- flow. An arch is sometimes referred to as
ter a deeper understanding of the importance a bridge or dome. When material arches,
of feeder design, this article discusses mate- sometimes the only way to address it is to
rial flow basics, flow patterns, the key role of employ a drastic means of flow promotion,
bin design, the types of feeders commonly such as vibrators, fluidization and unfortu-
used and devices available in the market- nately, sledgehammers.
place. In addition, it includes a list of feeder- Typically, a rathole develops when flow is
related dos and donts and finally a flow initiated and the material flows for a short
chart used to determine the correct feeder for time, then stops. Consider that friction de-
an application (see flowchart, p. 42). velops between the material and the hopper
wall surface such that, if the hopper wall is
Flow problems too rough or too shallow (or both), the ma-
Several flow problems can occur in bins and terial will not slide. When this occurs, a flow
silos, including the following: channel develops. Usually this channel forms
No flow due to arching and ratholing straight up into the material, but it can also
Erratic flow travel off to one side. If the solid material has
Flooding or flushing cohesive strength, the flow channel will empty
Flowrate limitations out and form a stable pipe that is referred to
Segregation as a rathole. Like arching, collapsing a rat-
These problems are discussed further below. hole requires extreme measures. The effects
Arching and ratholing. In some situations, of these measures on the structure of the bin
flow is initiated from the bin, and it either or silo should be considered. Collapsing ra-
does not flow at all or perhaps flows for a tholes can release tremendous amounts of
short time and then abruptly stops flowing. material, which can cause silos to fail.
When this occurs, the material is in a no-flow Erratic flow. The problem of erratic flow is a
condition due to the formation of an arch or combination of arching and ratholing. If the
NSF/ANSI 61
CERTIFIED
Proco Products, Inc. continues to
bring you the best in rubber expansion
joints for potable water systems.
T
he following represent practices to employ, and others to avoid, Dont mistake a conveyor for a feeder. Often, conveyors are as-
when designing and choosing feeders and related equipment. sumed to be feeders. A feeder is designed to operate nearly 100%
Do measure flow properties. Material flow properties are re- full; whereas, a conveyor would typically operate at less than, say
quired to determine your materials cohesive properties, wall friction 40% capacity to provide conveyance.
properties and compressibility. These properties provide necessary Do account for loads on a feeder. Feeder loads can be tricky. For
information for proper design of your feeder. instance, consider a bin with a properly designed mass-flow screw
Dont choose the wrong feeder. You would not want to use a belt feeder that has initially been filled with your material. Be aware that
feeder when handling floodable materials. Likewise, you would not initial fill loads require increased torque to turn the screw. This initial fill
use a screw feeder to handle friable products. pressure can require 2.5 times the running torque to start the screw.
Do design for mass flow. The bin and feeder must work in unison. Dont use constant-pitch flights. Constant-pitch screws are
If the bin is not designed to ensure mass flow, the feeder will be deal- notorious for developing preferential flow channels. The back flight
ing with funnel flow and ratholing, erratic flow, flooding and segrega- (away from the discharge end) fills with material and the succeeding
tion issues. Likewise, if the feeder is designed improperly, flow from flights being constant pitch, do not have the capacity to take any
the bin will be affected negatively. more material and material does not flow over the entire bin outlet,
Dont assume that one feeder is suited to all solids.You may only the back.
need to discharge at high flowrates. This would likely require a slot- Do ensure increasing-capacity geometries. A screw or belts
ted opening with either a belt or screw. If you need to discharge to a success is dependent on increasing the capacity of the equipment
pneumatic conveying system, a rotary airlock will be required to seal in the discharge direction. With a screw, this is done by varying the
against a positive pressure gradient. You would not want to use a belt flight pitches, and on a belt, by using an interface design that pro-
or screw to do this. vides the increase in capacity required for uniform flow.
Do consider material consistency. If you are handling a low den- Dont sacrifice quality for low cost. We all have to work within
sity product or require low discharge rates, you may want to con- budget constraints. But purchasing an incorrectly designed feeder
sider a pan feeder to provide uniform discharge. If your material is because it was less expensive can lead to severe handling problems
dusty or toxic, a properly designed screw feeder will be useful. down the road. n
in the discharge direction. This can be ac- from back to front. This allows more mate-
complished through a properly designed in- rial to be deposited on the belt toward the
terface between the bin outlet and the belt. discharge end of the bin. Additionally, the in-
This interface uses gradually rising interface terface increases in width from back to front,
PROTECT PUMPS
DRYRUNNINGCAVITATIONBEARINGFAILUREOVERLOAD
PUMPING
AMPS
Circle 27 on p. 98 or go to adlinks.chemengonline.com/66433-27
Circle 40 on p. 98 or go to adlinks.chemengonline.com/66433-40
Choosing
Agglomeration
Equipment
A products intended use often dictates what type of agglomeration equipment should be used.
Presented here is a discussion of the main types of equipment and methods for forming agglomerates
A
gglomeration is the process of con- Feeco International Greg Mehos
verting fine powder particles into University of Rhode
larger ones through the introduction Island
of external forces. Agglomeration Chris Kozicki
offers numerous benefits for bulk solids pro- Feeco International
cessors, including significant dust reduction,
improved handling, more complete utilization
of raw materials and densification. Agglom-
eration can be accomplished by a variety of IN BRIEF
means, including mixing with a liquid, apply- GENERAL PRINCIPLES
ing pressure and heating.
This article describes various technolo- TUMBLE-GROWTH
AGGLOMERATION
gies available for particle size enlargement.
The technologies fall into three general cate- PRESSURE
gories: (1) tumble-growth agglomeration, (2) AGGLOMERATION
pressure agglomeration, and (3) agglomera- TEMPERATURE AND
tion by heating or sintering. Tumble-growth SINTERING
agglomeration includes both wet and dry
methods. Stresses developed in pressure HANDLING
agglomeration equipment can range from AGGLOMERATED
FIGURE 1. This disk pelletizer is an example of a tumble- PRODUCTS
moderate to extreme. For some materials,
growth wet agglomaration technology, in which fine particles
agglomeration by heating or sintering can are wetted with a liquid, usually water FINAL REMARKS
be accomplished at relatively moderate
temperatures. An end products intended ital costs, but lower operating costs. The ag-
use often dictates what type of agglomera- glomerates formed by these methods have a
tion equipment should be used. higher bulk density, but they may be prone to
attrition if the pellets that are produced have
General principles sharp edges.
Tumble-growth agglomeration equipment Particles are held together by a number of
tends to have lower capital costs than the mechanisms. Solid bridges between particles
other methods, but costs may be higher if can be the result of sintering, partial melting
drying is required. Agglomerates produced and recrystallization during drying. Binders
by tumble-growth technologies tend to have that readily adhere to solid particles are ef-
a lower bulk density and a wider particle size fective agglomerating aids. Liquid bridges in
distribution as compared to other agglom- spaces between individual particles can form
eration methods. Binders frequently must be strong agglomerates as a result of capillary
added to ensure that green (that is, wet) forces that develop when the voids are com-
or dry agglomerates have sufficient strength. pletely filled with the liquid. Attractive forces,
Pressure agglomeration equipment, as such as van der Waals interactions, valence
well as equipment that agglomerate particles forces and hydrogen bridges can also hold
by heat or sintering, tend to have higher cap- solid particles together. If adjacent particles
BUNGARTZ
MASTERPIECES
EXPLOSION SAFETY
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Other details also catch the eye: it is hermetically sealed,
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Pressure agglomeration
Pressure agglomeration falls in two
general categories: roll compaction
and die compaction. Because attrac-
tive forces between particles intensify
Feeco International
Wet Milling
Wet
Reduce particle size to 20 nm
Easily clean between batches
Reproduce and scale your results
Dispersing
Mix
Circle 11 on p. 98 or go to adlinks.chemengonline.com/66433-11
CONFERENCE SESSIONS
The Connected Plant Conference is designed specifically to address the emerging trends and applications around
digitalization in the chemical process and power generation industries. Advances in data analyses, simulation,
modeling, modern sensors, virtual reality, mobile applications, computer networks, predictive instrumentation and
more are empowering companies to make great strides both technologically and in their business models.
Changes are happening quickly, and the time to learn more about how digitalization can be implemented
in your industry is now. POWER will co-host the power generation conference track. View the full agenda at
connectedplantconference.com/agenda
W
hile reducing fugitive emissions
Fluor Canada Ltd. is a leading concern in the fight
against climate change, emis-
sions continue to be released
IN BRIEF via leakage of process equipment in manu-
TESTING AND facturing plants and other operations in
IMPLEMENTATION many industrial sectors. Valve leakage is re-
DESIGNING FOR portedly responsible for more than 65% of
REDUCED EMISSIONS total fugitive emissions, by some estimates.
As a result, valves have been a consider-
FINAL CONSIDERATIONS
able area of focus in the effort to reduce
fugitive emissions.
So, where are the chemical process
industries (CPI) headed in the quest to
achieve reductions in fugitive emissions?
Regulators and end users are currently
working on developing, expanding and im-
proving several industry standards for fugi-
tive emissions and valve seals (Figure 1), as
summarized below:
ISO 15848: Measurement, Test and Quali-
fication Procedures for Fugitive Emissions
Part I Classification System and FIGURE 1. A great deal of effort has gone into developing
Qualification Procedures for Type industry standards aimed at reducing fugitive emissions from
Testing of Valves valve seals
Part II Production Acceptance U.S. and Europe. As a result of concerns re-
Test of Valves lated to emissions, the American Petroleum
API 622: Type Testing of Process Valve Institute (API; Washington, D.C.; www.api.
Packing for Fugitive Emissions org) worked to develop the API 624 standard
API 624: Type Testing of Rising Stem Type Testing of Rising Stem Valves Equipped
Valves Equipped with Graphite Packing with Graphite Packing for Fugitive Emissions.
for Fugitive Emissions Currently, ISO 15848-2 is the only production
API 641: Type Testing of Quarter-turn fugitive-emissions standard, and the norm is
Valves for Fugitive Emissions to test 3% of valves per line item using helium
Additional user-defined fugitive-emission at 100 psi. There have been several proce-
reduction requirements dural shifts required with the introduction of
API 624.
Testing and implementation API 624 was developed to cover multi-
Valve emissions are taken quite seriously turn valves, such as gate, globe and control
around the globe, particularly in Canada, the valves used in operating plants. The API 624
60 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Task Force worked for over two years ValvTechnologies Inc., USA
281-987-0726
www.dyna-therm.com
SEPARATION AND STEAM DRUM SOLUTIONS SINCE 1961
Circle 16 on p. 98 or go to adlinks.chemengonline.com/66433-16
Circle 26 on p. 98 or go to adlinks.chemengonline.com/66433-26
DESIGNING FLANGE
JOINT PARTS
L
eakage of bolted flange joints results FIGURE 1. Determining the shellside and tubeside operating
in additional costs at any facility in temperature at a particular location within the tubesheet is
an essential part of analyzing the potential for thermal shocks
the chemical process industries in flange joint parts
(CPI), and poses significant opera-
tional, environmental and safety risks. chemical processing plant. They are used
There can be many reasons for flange to transfer heat energy across metal walls
leakages, such as thermal shocks or dif- between hot fluids and cold fluids. Tubes,
ferential thermal expansion of compo- tubesheets and girth flanges are among the
nents, uneven bolt stresses, improper metal components that separate the fluids
flange alignment, improper gasket seating, and are exposed to varying-temperature
high vibration levels, incompatible materi- fluids in heat exchangers.
als and so on. Some of these causes can Large temperature differences between
be rectified by properly selecting materials the hot and cold fluids can cause thermal
or using the correct assembly techniques. distortion of these exposed components.
Some reasons, such as thermal shocks and Thermal distortion of girth flange-joint parts
high vibration levels, are direct results of is one of the major causes of fluid leakages
operating conditions. in shell-and-tube heat exchangers. There
This article outlines a basis for identify- are two main categories of thermal shock,
ing the thermal shock scenario in the girth outlined below.
flange joints of shell-and-tube heat ex- Temperature differential (TD) thermal
changers and the design measures that can shock. Thermal shock on girth flange
be adopted in mechanical strength calcula- joints due to the large temperature dif-
tions of flanges to minimize leakage due to ference between the two different flu-
thermal shocks in operational equipment. ids placed on the shellside and tubeside
Shell-and-tube heat exchangers are an of the exchanger is identified as TD in
essential part of any petroleum refinery or this article.
64 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
Small More
No rotation rotation rotation
Bowing
Circle 38 on p. 98 or go to adlinks.chemengonline.com/66433-38
passes 1 and 2 for shellside fluid at design calculations. and Pressure Vessel Committee (BPVC), Subcommit-
tee on Materials, ASME Section II, Part D Allowable
the tubesheet face. The temperature gradient around Stresses, 2017.
Average temperature (Tss34) = the channel-side flange compo- 3. ASME, PCC-1 Guidelines for Pressure Boundary
(Tss1 + Tss2)/2 = 150.61C nents, including the tubesheet, is: Bolted Flange Joint Assembly, Appendix O, 2013.
Average temperature (Tss12) = 4. Welding Research Council, WRC Bulletin 538 De-
(Tss34 + Tss2)/2 = 165.92C TG = Tts1 Tts2 = 281.21 187.39 termination of Pressure Boundary Joint Assembly Bolt
Loads, Section 4, p. 15, February 2014.
= 93.82 (< 110C)
5. Tubular Exchanger Manufacturers Association (TEMA)
The temperature differential across Standards, 9th Ed., Nov. 2007.
the tubesheet is calculated as follows: In the above example, the TD at 6. ASME BPCV Section VIII, Div. 1 Rules for Construction
At pass 1, TD = Tts Tss12 = pass 1 exceeds the API 660 limit, of Pressure Vessels, 2017.
281.21 165.92 = 115.29C so additional analysis of the chan- 7. Heat Transfer Research Inc. (HTRI) design software and
(Since this is greater than 110C, nel-tubesheet-shell flange joint is documentation, www.htri.net.
additional mechanical analysis re- required. The use of these design Author
quired for flange joint parts). augmentations, along with adher- Pankaj Kumar Singla is a
At pass 2, TD = Tts Tss12 = ence to industry codes and stan- mechanical design engineer for
Fluor Daniel India Pvt. Ltd. (6th
221.98 165.92 = 56.06C dards and rigorous design soft- Floor, Infinity Tower B, Cyber City,
(< 110C) ware, will help to evaluate, and DLF City Phase II, Gurgaon 122
Similarly, at passes 36, TD = perhaps even eliminate, the poten- 002, Haryana, India; Email:
pankajsingla99@gmail.com;
Tts Tss (< 110C) tial for damaging thermal shocks Phone: +91-97164-14125). Sin-
and distortions in the critical inter- gla has more than nine years of
experience in the detailed engi-
It should be noted that the aver- nal components of shell-and-tube neering of static equipment in the pre-bid phase, as
age of operating temperatures at heat exchangers. well as front-end engineering design (FEED) and de-
the shellside, as assumed in this Edited by Mary Page Bailey tailed engineering for various oil-and-gas, petroleum
refining and petrochemical industry projects. Prior to
case, may not be applicable for joining Fluor, Singla worked as a static equipment engi-
other cases. Therefore, use of the References neer for Daelim Industrial Co. (South Korea) and as a
shellside fluid temperature at des- 1. American Petroleum Institute, API Standard 660 Shell- senior engineer at Valdel Engineers & Constructors
and-Tube Heat Exchangers, 9th ed., March 2015. (India). He holds a B. Tech. degree from the Giani Zail
ignated locations must be carefully Singh College of Engineering & Technology in Bathinda,
evaluated before being adopted into 2. American Society of Mechanical Engineers (ASME) Boiler Punjab, India.
CHEMICAL
ENGINEERING
ESSENTIALS FOR CPI PROFESSIONALS
V pCI-649 is an environmentally
friendly, nitrite-free corrosion
inhibitor for use in systems con-
one piece, through a very large de-
gree of prefabrication in the plant.
The family business was recently
taining fresh water or glycol. It able to demonstrate its longstand- The very high degree of
can be added at low doses to ef- ing experience by producing two col- prefabrication benefited
fectively and economically protect The combined contact umns for a German chemical park. the customer.
ferrous and non-ferrous metals and vapor phase action BUTTING obtained an order for
from corrosion in closed loop sys- of corrosion inhibitors in the production of two columns. The
tems, or in vessels that have been VpCI-649 protect closed-loop processing engineering equipment in the form of a hollow, slender
hydrostatically tested. The vapor system internals below and column has special fittings, as required by the application or the op-
phase action of this unique con- above the surface of the water. erating conditions. Both columns were prefabricated in Knesebeck:
centrated liquid protects against The first column, 25 metres long and 1 400 mm in diameter, was
corrosion in areas that traditional produced in two parts, as was the second column, which was much
contact-only corrosion inhibitors cannot reach. VpCI-649 also con- smaller, 15 metres long and 1 000 mm in diameter.
tains an acrylic polymer to prevent scale formation. The large number of fittings presented a special challenge: A
VpCI-649 is an especially important tool for protecting intricate total of more than 190 metres of welding wire had to be welded
internal surfaces from corrosion during hydrostatic testing. A cost- for the inner fittings. Robert Lenz, Spools & plant construction, ex-
effective dose of VpCI-649 can be easily added to pipelines, casings, plains: A large number of branches were welded on one side. In so
tanks, and valves; circulated; and drained. This leaves behind a pro- doing, very tight tolerance requirements had to be complied with,
tective layer on the system internals for continued protection of up to in order to guarantee the parallelism of the inner fittings. In addi-
two years. tion, carbon steel support feet had to be welded to one end of each
column.
www.cortecvci.com www.butting.com
ROTOFORM FEATURES
Every aspect of the Rotoform system has
been designed to ensure not only premium
Functional Safety
quality pastilles, but also low operating
costs and minimal environmental impact. FLEXIM offers the worlds first
The system has high availability, between SIL 2-certified clamp-on flowmeters
8,500 and 8,700 hours per year. Unlike com-
petitive systems, individual Rotoform units
can be stopped for cleaning or maintenance
without shutting down the entire plant,
A s the worlds first ultrasonic clamp-on flowmeters, the
FLUXUS series from FLEXIM have proven their suitability for
use in process control protection equipment according to the IEC
yielding lower operational costs. To make 61508 norm and are certified as SIL 2 capable.
maintenance even simpler, the Rotoform The FLUXUS F/G70X and F/G80X series meters, which are to
pastillator unit uses just two motors. be used for the permanent, non-invasive flow measurement of
The Rotoform granulation system also liquids and gases, are audited and certified. Since clamp-on ul- Measuring with FLUXUS
provides an environmentally-friendly process trasonic transducers are simply attached to the outside of the pipe means measuring
with low sound emissions, low dust emissions, wall, the measuring system is not exposed to any wear and tear by on the safe side
and no need for air cleaning. Furthermore, the the medium flowing inside and is thus virtually maintenance-free.
closed cooling water system means there is In addition to that, there is no need to open the pipe when installing the clamp-on flowmeter
no possibility of cross contamination between and therefore no interruption to production or processing.
water and end product. Noise levels are below Due to the ultrasonic transit-time technology used, the measurement works bidirectionally
85 dB(A), dust emissions are under 5 mg/m3, with the same high degree of accuracy over an extremely high dynamic range. FLUXUS clamp-
and electrical consumption is just 4 kW per ton on meters measure independently from the medium flowing inside the pipe, as well as the
of urea. pipe material, its dimension and wall thickness and the operating pressure. It goes without
saying, the SIL 2-certified measurement systems are also offered in versions approved for use
CHEMICAL APPLICATIONS in potentially explosive atmospheres (ATEX, IECEx Zone 1 and 2).
The Sandvik Rotoform system is widely In conjunction with the patented transducer mounting fixture WaveInjector, the FLUXUS
used across the chemical and fertilizer meter can also measure at extreme pipe wall temperature ranges from -170 C up to 600 C.
industries for products such as sulphur Thanks to carefully matched transducer pairs, unique internal temperature compensation and
bentonite, fatty alcohol blends, hot melt ad- sophisticated internal signal processing, clamp-on ultrasonic FLUXUS meters are highly zero-
hesives, and various wax products. point stable and drift-free, ensuring precise measurement data.
www.sandvik.com www.flexim.com
Schenck Process
www.schenckprocess.com/us
Circle 01 on p. 98 or go to adlinks.chemengonline.com/66433-01
Circle 02 on p. 98 or go to adlinks.chemengonline.com/66433-02
W
ithin the technology
category of analyzers,
spectrometers provide Sample property Sample spectrum
a broad range of analyti-
cal capabilities and are available in
an extensive range of designs from
numerous suppliers. Spectroscopy Property correlation
has two main categories: atomic and FIGURE 1. The best situation is where there is a direct and distinct relationship between the spectro-
molecular. Both examine the interac- scopic analysis and the specific property being measured. In such a scenario, the spectrum accurately
tion between electromagnetic radia- reflects the property under investigation
tion and the sample being analyzed. his or her grain harvest to the local rate measurements.
Atomic spectroscopy looks for grain elevator. The buyer can take a Far more difficult is the application
specific elements that are present in sample of the corn or wheat and use of molecular spectroscopy to as-
samples without regard to their a near-infrared (NIR) spectrometer to sess the characteristics of gasoline,
chemical form. For example, refin- check for critical attributes, such as which is one of the most chemically
ers must determine and certify the moisture and food value in the form complex products. Gasoline is not a
sulfur content in diesel fuel. Though of oil and protein. The final price will single compound, but is a mixture
sulfur can be a component in doz- likely be influenced by these quality of hundreds or thousands of differ-
ens of different compounds that are measures, and the analysis can be ent hydrocarbon molecules. Trying
present in the fuel, atomic spectros- done in a matter of minutes. to measure various characteristics
copy selectively excites and detects Another example could be a phar- such as octane rating is not
all sulfur atoms regardless of how maceutical producer trying to deter- easy. This article examines the use
they are bonded in larger molecules. mine the moisture level in granules of spectroscopy for this situation.
This aggregated value satisfies the being processed in a dryer prior to
regulators objective to measure the tablet production. The technician Characteristics and spectra
overall sulfur content of the fuel. can try to calculate it by measur- Chemical producers are always
By contrast, molecular spectros- ing the humidity of the air leaving looking for better ways to measure
copy examines the chemical bonds the dryer, but the NIR spectrometer some property of interest in a prod-
that are present in compounds. In- provides a direct measurement that uct. This can take countless forms.
stead of exciting specific atoms, this is automated, rapid and precise. Picture a moonshiner loading a new
technology elicits telltale signals from Meanwhile, the device can be in- batch of fermented mash into a still.
the bonds between atoms. For ex- stalled to perform the measurement He wants to know how much etha-
ample, methane gives distinct sig- online and provide measurements nol is in the mash, so he watches
nals because of the characteristic in realtime, allowing the process to the temperature closely as it heats
way the bonds between its carbon stop immediately once the desired up. Why? Because he knows there
and four hydrogen atoms respond to level has been reached. is a direct and distinct relationship
electromagnetic radiation. These are relatively simple pro- between the boiling point of the mix-
This discussion focuses on mo- cesses. Moisture is very easy to ture and the proportion of ethanol to
lecular spectroscopy. Quantitative measure. Grain is a bit more com- water. The composition is expressed
molecular spectroscopy is used in a plex, but a kernel of corn will have a by the boiling point.
wide variety of applications in many short list of key attributes. Although A professional distiller could use
industries. Most relate to chemical there may be a variety of similar but a spectrometer instead of monitor-
quality assessments, such as exam- technically different oils, they still ing temperature, because the spec-
ining a product to ascertain the de- tend to show up together, and an trum it generates will have features
sired component proportions, or the aggregate reading is valid for the ap- that correlate clearly and directly
presence or absence of compounds plication. When the list of possible with component volumes. Similarly,
that are considered to be contami- chemical components grows, so an engineer may desire to control a
nants. Consider a farmer bringing does the difficulty of making accu- chemical process on the basis of a
86 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
FIGURE 2. Gasoline is one of the most chemically
complex products. Different batches can contain
hundreds or thousands of individual components
mixed in various proportions. The signature shown
here represents what is coming out of a particular
known dependence of product qual- proper NCO-to-OH ratio in reactions gasoline-blending unit today. However, tomorrow
ity or performance on some specific with isocyanate. The spectrometric the signature will likely be different, as the compo-
nent streams are tweaked, but the gasoline stream
molecular property. Often, online analysis of hydroxyl number in a min- will still meet its requirements. Is it possible to de-
molecular spectroscopy can be im- ute is possible because of a direct termine critical characteristics (that is, octane rat-
plemented to measure that property. correlation with the NIR signal for the ing or Reid vapor pressure), from this signature?
A good example is a production hydroxyl group in the polyol.
unit making polyols for use in poly- Though gasoline is chemically in gasoline spectra measured by
urethane foams or sealants. The complex, benzene can be measured Fourier transform infrared (FTIR) or
hydroxyl value must be controlled because it is one of the few com- Raman spectroscopy techniques.
to tight specifications to ensure the ponents that expresses itself clearly Some compounds, because of vari-
www.cashco com
Cashco, Inc. Innovative Solutions
Circle 08 on p. 98 or go to adlinks.chemengonline.com/66433-08
FIGURE 3. The analyzer with its chemometric model may be able to find a correlation, but does the cor-
ROTOFORM relation necessarily indicate a genuine cause-and-effect relationship?
GRANULATION ous quirks of nature, are much easier The application of such chemi-
to spot than others. cal thinking leads to the reasoned
FOR PETROCHEMICALS conclusion that modeling techniques
AND OLEOCHEMICALS Hard vs soft correlations can be combined with molecu-
The examples discussed thus far lar spectroscopy techniques such
rely on distinct spectral expressions as NIR, FTIR, Raman, and nuclear
of chemistry that support hard, magnetic resonance (NMR) to pre-
first-principles correlations. Unfortu- dict octane value for gasoline (Figure
nately, measurements often arent 2). Each technique gives a spectrum
so simple. In many situations, users that encodes information about the
want to measure properties where amounts of the different hydrogen-
the spectral expression is far less carbon structures that determine
distinct. In other words, the chemical how gasoline reacts with oxygen
signals are often buried in the sam- when in burns in an engine. Model-
High productivity solidi cation of ple spectrum. Fortunately, statistical ing based on such thinking is referred
products as di erent as resins, hot modeling tools are available to help to as chemometrics. Though models
melts, waxes, fat chemicals and users infer what they need to know. for octane are soft, they neverthe-
caprolactam has made Rotoform the
Instead of being hard, the corre- less are grounded in first principles
granulation system of choice for
lations obtained by inferential spec- of chemistry and spectroscopy.
chemical processors the world over.
trometry are considered, to varying
Whatever your solidi cation
requirements, choose Rotoform for
degrees, to be empirical or soft. Circumstantial correlations
reliable, proven performance and a
Development of statistical models The same user applying the same
premium quality end product. may require data from a few dozen techniques finds it possible to gener-
samples, or a few hundred. The ate a correlation with PTM results for
High productivity modeling software extracts math- sulfur in gasoline at levels below 200
on-stream factor of 96% ematical relationships between pri- parts per million (ppm). Yet, just as
Proven Rotoform technology mary test method (PTM) values and with diesel, sulfur in gasoline can be
nearly 2000 systems installed spectra measured for samples in a measured by atomic spectroscopy
in 30+ years calibration set (Figure 1). that counts sulfur atoms, while mo-
Complete process lines or That said, there needs to be cau- lecular spectroscopy methods can
retro t of existing equipment tion, because the statistical modeling only measure bonds between sulfur
Global service / spare parts supply techniques used are extremely pow- and other atoms. Applying chemical
erful and users can get into trouble thinking, the user will conclude that
when they assume they have a valid the correlation is not grounded in first
measurement simply because they principles and is therefore unsuitable
have a correlation. Relationships can for inferring sulfur in gasoline. Appar-
be abstract; still, chemists and engi- ently the correlation with ppm values
Sandvik Process Systems neers can and should form conclu- for sulfur is not due to correlation
Division of Sandvik Materials Technology Deutschland GmbH
Salierstr. 35, 70736 Fellbach, Germany sions if they have seen sufficient evi- with signals for sulfur. Instead, it is a
Tel: +49 711 5105-0 Fax: +49 711 5105-152
info.spsde@sandvik.com
dence to indicate that components circumstantial correlation rooted in
www.processsystems.sandvik.com
responsible for a property express unknown underlying factors.
themselves spectrally. A biochemical engineer desiring to
Circle 41 on p. 98 or go to adlinks.chemengonline.com/66433-xx
apply NIR or Raman spectroscopy across some range of frequencies. OKTALINE ATEX
in an effort to monitor a fermenta- Second, the purpose of the cor-
tion process used to produce an relation model is to convert the raw Magnetically coupled
antibiotic will be initially encouraged data into a concentration or property
by correlations that are generated value with specific attributes so the Roots pump combines
for nutrients or products in the fer- user is able to determine its action- a magnetic coupling with
mentation broth. But as with sulfur ability for purposes of process con- category 2 or 3 explosion
in gasoline, good statistics do not trol. Principle among them is track-
guarantee good measurements. ing process changes accurately and protection
Interestingly, both the refinery and in realtime.
the fermentation applications have a The subtlety is that a spectrometer Explosion safety due to reliable
common characteristic: it is impos- is actually not an analyzer any more construction and temperature
sible not to get a correlation, even than a temperature sensor is an ana- monitoring installation without
for chemical properties unable to lyzer. Both merely report an intensive additional flame arrester possible
express themselves spectrally. As property of the sample, though the Hermetically sealed (leakrate
Ronald Coase, 1991 Nobel laure- spectrometers response has many < 10-6 Pa m3/s) risk of zone
ate in Economics once observed: points instead of one. entrainment is minimized
Torture the data, and it will confess This idea is well understood by pro- ATEX protection in case of passive
to anything. cess engineers who use inferential rotation
Whats the culprit? Data sets that analyzers, also called soft sensors. Flexible application pump can
yield property correlations are them- This technology is applied in diverse start against atmospheric pressure
selves the product of highly corre- industries ranging from petroleum Pressure surge resistance accord-
lated processes. In the fermentation refineries and chemical plants to ing to EN 1333, PN level 16
broth example, an increase in one cement kilns, food processing, and
compound is accompanied by in- nuclear plants (http://www.springer.
creases or decreases in one or more com/us/book/9781846284793).
other compounds. The refinery is an Readings from multiple sensors in-
assemblage of interconnected units stalled throughout a process are
that produce components that can gathered to form a sort of spectrum,
be blended to make gasoline. an array of intensity values. Typically,
these readings come from simple Are you looking for a
Reading too much into the data univariate process sensors reporting perfect vacuum solution?
Before we dig further into the mat- temperature, pressure, flow, density, Please contact us:
ter, lets note two points that are both conductivity, current, motor torque,
obvious and subtle. First, the spec- opacity and more. Taken together, Pfeiffer Vacuum GmbH
trometer has only one purpose these individual data values are then Headquarters/Germany
namely, to measure a sample spec- used to model a process property of T +49 6441 802-0
trum, which is simply an X-Y data interest, such as degree of conver- www.pfeiffer-vacuum.com
array comprising intensity values sion in a batch reactor, or the quality
Circle 35 on p. 98 or go to adlinks.chemengonline.com/66433-35
HDC Hi-FLOW
DRY-RELEASE COUPLINGS
TM
Circle 30 on p. 98 or go to adlinks.chemengonline.com/66433-30
USA
91
T . 1 . 8 5 6 ENGINEERING
CHEMICAL .768.2275 F. 1.856.768.2385
WWW.CHEMENGONLINE.COM s a l e s @2017
OCTOBER novaflex.com www.novaflex.com
Show Preview
T
he 2017 Chem Show, tak- The following are some highlights of
ing place from October 31 to the products that will be exhibited at
November 2 at the Jacob Ja- the 2017 Chem Show.
vits Center in New York City,
will focus on all types of processing This CIP tank cleaner operates
equipment used across the breadth while fully submerged
of the chemical process industries The new TankJet 78 tank cleaner
(CPI). The show will feature over 300 (photo) provides fast, high-impact
exhibiting companies and a broad- cleaning of tanks up to 45 ft in diame-
ranging seminar program. As part of ter. TankJet 78 systems are available
its seminar program, the Chem Show in single-hub (two-nozzle) or dual-
will host presentations from the 2017 hub (four-nozzle) designs. The unit
finalists for the Kirkpatrick Chemi- is built to withstand extremely harsh
cal Engineering Achievement Award, chemicals and can operate while
which is given every two years by fully submerged. It features a thread-
Chemical Engineering to honor the less, crevice-free and self-cleaning
most noteworthy chemical engineer- design, which takes just minutes
ing technologies to reach commer- to disassemble, without tools, for
cialization. The finalists were selected easy maintenance, says the com-
by a panel of judges consisting of pany. Providing 360-deg coverage
chemical engineering department of tank interiors, the unit is suitable
heads at accredited universities. Each for clean-in-place (CIP) applications.
finalist company will give a presenta- Booth 312 Spraying Systems Co.,
tion outlining their nominated tech- Wheaton, Ill.
Spraying Systems
nology during the Chem Show on www.spray.com
November 1. The 2017 Kirkpatrick
finalists and their technologies are Use this mill in either wet or dry
summarized below: granulation processes
CB&I and Albemarle are nominated The Kek cone mill (photo) can han-
for a jointly developed solid-catalyst dle a wide range of feed material to
alkylation process that eliminates produce diverse products for inter-
the hazards associated with han- mediate sizing in both wet and dry
dling liquid acids granulation processes. According
Chemetry is nominated for the to the manufacturer, the Kek cone
eShuttle technology, which aims to mill provides a gentle, low-energy
make the chlor-alkali product chain form of size reduction and eliminates
safer and more efficient by generat- traditional milling problems, includ-
ing no chlorine ing noise, dust and heat. The gentle
Dow Coating Materials is nomi- grinding action is capable of control
nated for the Canvera polyolefin- within fine limits while maintaining a
dispersion coating technology used close particle-size distribution with
to protect against leaching from minimal fines generation, typically
metal containers grinding from 25 mm to 250 m.
Dow Coating Materials is also a Booth 215 Kemutec Group Inc.,
finalist for the new Paraloid Edge Bristol, Pa.
technology that produces urethane www.kemutecusa.com
coatings without isocyanate or
formaldehyde This metering pump is protected
Kemutec Group Microvis nominated technology against suction blockage
is the Denitrovi biocatalytic nitrate The MT8 triplex metering pump
removal process, which safely de- (photo) is the newest model in the
grades nitrates from drinking water Hydra-Cell product line. The MT8
without the formation of sludge is designed to handle a wide range
Praxair is nominated for its Op- of processing fluids at low flowrates
timelt thermochemical regenera- and features a multiple-diaphragm
tor process, which is an oxy-fuel design to provide virtually pulse-free
glass-melting technology that uses flow without the need for pulsation
endothermic chemical reactions for dampeners. It is said to exceed
Wanner Engineering waste-heat recovery API 675 performance standards
92 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2017
for steady-state accuracy (1%), linearity (3%) and
repeatability (3%), according to the manufacturer.
Flow capacity for the MT8 ranges from 0.06 to 8.0
gal/h with discharge pressure ratings up to 3,500
psi (241 bars), depending on flow requirements. A
built-in pressure-relief valve and replenishment valve
system protect the pump in the event of blocked
suction. Booth 605 Wanner Engineering Inc.,
Minneapolis, Minn.
www.hydra-cell.com
SPECIAL REPORT
Digitalization
in the Chemical
Process Industries
This special report contains recent news articles (2017) from Chemical Engineer-
ing magazine that give a timely and informative overview of digitalization as well as
a number of articles (2016) on related cybersecurity issues..
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PELLETING
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ufm@flowmeters.com Talk Directly with Design Engineers!
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Technology Leader, air pollution control
Since 1960 Factory and Headquarters: Owosso, Michigan 2017 Tri-Mer Corp.
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Abbe, Paul O. ......................... 12 Emcor Group ...........................4 Pfeiffer Vacuum GmbH ..........89
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* International Edition
Send Advertisements and Box replies to: Diane Burleson
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(1957-59 = 100) July '17 June '17 July '16 Annual Index:
Prelim. Final Final
2009 = 521.9 600
CE Index ______________________________________________ 569.6 566.6 544.9
Equipment ____________________________________________ 686.7 683.2 650.4 2010 = 550.8
Heat exchangers & tanks _________________________________ 603.6 602.8 560.3
2011 = 585.7 575
Process machinery _____________________________________ 685.9 681.5 652.7
Pipe, valves & fittings ____________________________________ 876.6 867.3 822.8 2012 = 584.6
Process instruments ____________________________________ 404.0 403.6 389.2 2013 = 567.3 550
Pumps & compressors ___________________________________ 984.7 985.1 970.1
Electrical equipment ____________________________________ 520.8 513.4 510.7 2014 = 576.1
Structural supports & misc. ________________________________ 739.9 737.4 707.9 2015 = 556.8 525
Construction labor _______________________________________ 330.3 327.2 328.9
Buildings _____________________________________________ 561.6 559.6 546.8 2016 = 541.7
Engineering & supervision _________________________________ 313.8 312.9 314.4 500
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.
CURRENT TRENDS
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