Chemical Engineering

HPS sRe_Chem Eng Ad 11-07
10/10/07
4:17 PM
Page 1
HPS sRe_Chem Eng Ad 11-07Pub: Chemical Engineering
reliability
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optimally and increase visibility across the enterprise to

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within safe limits. Honeywells solutions to increase reliability
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2007 Honeywell International, Inc. All rights reserved.
Circle 01 on p. 58 or go to adlinks.che.com/7368-01
Cover 2 CHE 1-08.indd 2
12/13/07 3:21:25 PM
Color: 4c
Honeywell solutions keep your plant and assets running
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Using Honeywells solutions, an ethylene plant

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1 CHE 1-08.indd 1
12/17/07 3:27:05 PM
2 CHE 1-08.indd 2
12/13/07 3:26:06 PM
JANUARY 2008
IN THIS ISSUE
COVER STORY
30 Cover Story
www.che.com
Controlling SO2
Without Corroding
the Bottom Line
Mist Eliminators in wet
scrubbers comprise a
large portion of system
operating costs. Consider these material
selection and replacement criteria to curb
chronic maintenance
requirements
VOLUME 115, NO. 1

COMMENTARY
5 Editors Page
2008: Climate still
on the plate A
number of policy
developments are in
the works, and CPI
companies appear to
be taking their own
initiatives
DEPARTMENTS
Letters . . . . . . . . . . . 6
Bookshelf . . . . . . . . 8,9
NEWS
Whos Who. . . . . . . 28
11 Chementator Save space, money and water with this new clarifier process; A new off-shore
Reader
Service page . . . . . . 58
GTL production system takes advantage of microchannel reactors; This CO2-recovery process
set to enhance EOR; Using living plants to synthesize metallic nanoparticles; This solar reactor
will recycle carbon dioxide; Purification of single-walled using froth flotation; Commercialization is set for a Fischer-Tropsch process; Turning dishwashing waste into fuel; and more
16 Newsfront Outlook for 2008 & 2009

ACC's chief economist says growth will
moderate in the near future
21 Newsfront Cleaning Up With Catalysts

As worldwide regulations grow more stringent, catalyst development focuses on providing cleaner energy sources and cleaning
up air pollution
25 Newsfront Call For Nominations: Personal

Achievement Award Help us honor distinguished careers in chemical engineering
ENGINEERING
27 Facts At Your Fingertips Sedimentation

Centrifuging This one-page guide outlines
the fundamental concepts behind sedimentation centrifuging as well as a comparison
of common centrifuges
38 Feature Report Integrated Computerized Maintenance Management Systems For Effective Plant Performance
Controlling gigabytes of predictive maintenance data isnt easy, but its essential for
streamlining your process
42 Engineering Practice Corrosion Resistance Using Rock and Glue Low-cost,

corrosion-resistant castings are being produced using epoxy and mineral aggregates
44 Engineering Practice Seal-Fluid-Circulation Devices: Understanding the Differences Knowing the options in fluid-circulation designs helps in the selection process
48 Operations and Maintenance Technology and Scheduling: The Perfect Chemistry By utilizing efficient scheduling software, companies in the CPI can improve
enterprise agility and compliance
Economic
Indicators . . . . . 59, 60
EQUIPMENT & SERVICES
ADVERTISERS
ADV
28D-1 New Products & Services
Italy Advertorial . . . 28I-5
(Domestic Edition) This dye

injector fits the needs of large
refrigeration systems; Nanosilica improves the
physical properties of this epoxy; These ball
bearings are designed for universal mounting; Use this industrial toggle switch over a
range of power levels; Release pure compounds into solution at a steady rate;
Measure temperatures up to 300
from a distance; and more
28I-1 New Products & Services

(International Edition) Take
full advantage of continuous
processing with this new
reactor; A new controller for
when safety is especially important;
Take this particle analyzer where and when
its needed; Don't let gas disrupt your dosing
operation; The latest in RFIS antennas; Valves
for LNG transportation; Up to 32 field devices
are handled by this transmitter; Sunlight does
not impede the accuracy of this transmitter;
This turbopump is suitable for processing
electronics chemicals; and more
46 Focus Mixers A single planetary mixer for high viscosity

paste materials; Less dry
powder on the surface of
liquid dispersions with this
mixer; Mix multiple tanks
easily with this air-operated
stand; An oversized output shaft makes
this agitator less noisy and more efficient;
Achieve thorough, gentle and short residence
times with this mixer; and more
Product Showcase . . . 50
Classified
Advertising . . . . .5156
Advertiser Index . . . 57
COMING
IN FEBRUARY
Look for: Feature
Reports on CPI WaterSteam Chemistry; and
Recommended Safety
Practices for Pumps
Handling Hazardous Liquids; A Solids
Processing article on
Coatings for Bins &
Silos; An Environmental Manager article on
Hydrocarbon Leaks in
Cooling Water Systems
Effects and Remedies; A You and Your
Job article on When
It Becomes Necessary
to Fire an Employee; A
Focus on Flowmeters;
News articles on Electronic Chemicals; and
Asset Management;
Facts at Your Fingertips on Pressure Relief;
and more
Cover: David Whitcher
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:3
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4 CHE 1-08.indd 4
12/13/07 3:18:09 PM
Winner of Eight Jesse H. Neal

Awards for Editorial Excellence
Published since 1902
An Access Intelligence Publication

PUBLISHER
ART & DESIGN
NELLA VELDRAN
DAVID WHITCHER
EDITORS
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Jenike & Johanson, Inc.
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MixTech, Inc.
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IIT Madras, India
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CONFERENCES
TREVOR KLETZ
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Fluor Corp.
Loughborough University, U.K.
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DECHEMA e.V.
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BOC
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Editors Page
2008: Climate still on the plate
n a ceremonious sense, the marking of a new year thankfully lets us put

certain things to rest and look ahead to a fresh start. At the same time,
a majority of the previous years challenges are still at hand if not
intensified. The latter is certainly true for the chemical process industries
(CPI) in a broad sense and is especially the case this year in the context of
greenhouse gas (GHG) emissions and climate change.
On a policy level, several key developments promise to shape the coming
year. Last month, 187 countries, including six heads of state, met at the
Thirteenth Conference of the Parties in Bali to launch negotiations toward
a new climate-change prevention deal, which would follow the expiration of
the first phase of the Kyoto Protocol in 2013. The outcome defines an agenda
for the following key issues to be negotiated up to 2009: action for adapting
to the negative consequences of climate change, such as droughts and floods;
ways to reduce GHG emissions; ways to widely deploy climate friendly technologies; and financing both adaptation and mitigation measures. Parties
for the first time considered the possible inclusion of carbon capture and
storage (CCS) in geological formations for clean-development-mechanism
(CDM) qualification (a way for developed nations to achieve emission reduction credits through investment in developing countries).
During the Bali conference, Australias recently elected Prime Minister,
Kevin Rudd, completed ratification of the Kyoto Protocol, leaving the U.S. as
the only developed nation in rejection of it. Rudds predecessor, John Howard,
stood ground with U.S. President Bush, on the basis that the treaty unfairly
penalizes developed countries by making no demands of fast-growing emerging
economies such as China. According to the White House press secretary, the
U.S. joins the Bali consensus decision, but still has concerns that more weight
should be given to the principle of common but differentiated responsibilities.
Even if matters like these keep the worlds largest emitter from ultimately
ratifying Kyotos successor, there is growing evidence that, within the CPI at
least, companies are reducing GHGs with and without legal mandates. For instance, in response to a U.S. Senate Committee cap-and-trade bill that will come
before a full Senate vote this year, the American Chemistry Council (Arlington,
Va.; www.americanchemistry.com) points out that its members have reduced
absolute GHG emissions by 12.5% and improved energy efficiency by nearly
27% since 1990, exceeding even what the Kyoto Protocol would have required.
And as the following examples illustrate, GHG reduction initiatives continue
to mount on a company level. Bayer AG (Leverkusen, Germany; www.bayer.
com) has launched an integrated, group-wide Bayer Climate Program to further reduce CO2 emissions from its production facilities and develop new solutions for mitigation. The program includes a `1-billion investment in climaterelated research and development and other projects over the next three years.
Between 1990 and 2006, Bayer says it reduced GHG emissions by 36%.
Last month at the U.S. EPAs Climate Leaders conference in Boulder Colo.,
Roche Group U.S. Affiliates (Basel, Switzerland; www.roche.com) pledged to
reduce its total U.S. GHG emissions by 15% from 2001 to 2010. Roche achieved
its initial goal by reducing its emissions by 11% from 2001 to 2006.
To support its goal to reduce GHGs by more than 20%
by 2015, The Dow Chemical Co. (Midland, Mich.; www.
dow.com) has announced plans to use a steam process that
captures CO2 emissions to be sold for enhanced oil-recovery use (also see p. 12). Meanwhile, Monsanto (St. Louis,
Mo.; www.monsanto.com) has joined the Chicago Climate
Exchange (CCX), the only legally binding emissions trading
program in the U.S. for GHGs. Plans include a 6% reduction
(or trade) in U.S. carbon emissions from 2000 levels.
O
Rebekkah Marshall
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:5
Letters
Opinion on ChE graduate shortages
Your editorial (Calling all chemical engineers, Sept., p.
5) on the subject of the lack of entrants to chemical engineering studies and careers invited readers to reply.
I think that this problem will not go away until the
industries desiring chemical engineers examine the
source of the problem.
In my opinion any high school leaver with more
brains than a sausage will have noticed the fact
that chemical engineers are downsized in wholesale
amounts. For instance, recently the pharmaceutical industry has tossed out piles of chemists and chemical engineers; the Wall Street Journal last [month] described
how Pfizer has thrown out the guys who developed
drugs and brought Pfizer billions.
Under the circumstances I cannot blame them for
choosing other, hopefully more secure, professions, and
ignoring we desperately need chemical engineers
type hype.
Regards,
Solly Zitron
Samuel Engineering, Inc., Greenwood Village, Colo.
TRFA call for papers

The Thermoset Resin Formulators Association (TRFA;
Glen Ellyn, Ill.; www.trfa.org) invites the submission
of technical papers for presentation at the associations
2008 Annual Meeting to be held September 1416 at the
Hilton Suites Chicago Magnificent Mile in Chicago, Ill.
The 2008 Annual Meeting schedule will include at
least three technical paper presentations from each
of TRFAs Market Focused Product Groups: coatings,
civil engineering and floorings; adhesives and sealants;
composites and tooling; and potting, encapsulation and
electrical. Technical papers are chosen based on their
technical content, the timeliness of the subject, and relevance to TRFA members and the industry. Attendees at
the 2007 Annual Meeting in Savannah, Georgia enjoyed
twelve technical paper presentations.
Persons interested in submitting a Technical Paper for
consideration should contact the association at (630)9426596 or info@trfa.org to request a Technical Paper Packet
for the 2008 Annual Meeting. Please note that abstracts
must be received no later than March 1, 2008.
Do you have
Ideas to air?
Feedback about our articles?
Comments about todays
engineering practice or education?
Job-related problems or gripes to share?
If so Send them, for our Letters column, to
Rebekkah Marshall
Chemical Engineering, Access Intelligence,
110 William St., 11th floor
New York, NY 10038; letters@che.com
6 CHE 1-08.indd 6
12/26/07 1:48:46 PM
Warning
this is no place for a leaky pump.
If youve got corrosives, pollutants, or toxics to pump, you really should consider upgrading to Goulds sealless
process pumps. Our metal (Model 3296) and ETFE-lined (Model 3298) magnetic drive pumps are designed for
optimum performance and emission prevention. Goulds Dryguard bearings will ensure safe operation through
short-term dry run conditionsthe main cause of magnetic drive pump failure. And
for the ultimate in protection, the ITT PumpSmart controller has the ability to monitor,
rapidly identify process upset conditions, and react to protect your mag-drive pump.
One more reason ITT should be your choice for all critical pumping needs. Call
1-800-734-7867 or visit gouldspumps.com for more information.
Goulds Pumps
7 CHE 1-08.indd 7
12/13/07 3:24:18 PM
Bookshelf
Introduction to Process Engineering
& Design. By S. B. Thakore and B. I.
Bhatt. Tata McGraw Hill, B-4, Sector
63, Distt. Gautam Budh Nagar, Noida,
UP-201301. Web: tatamcgrawhill.com.
2007. 768 pages, Rs 500.
Reviewed by Michael E. Ryan,

Department of Chemical and Biological Engineering, The State University
of New York, Buffalo, N.Y.
his book is intended as a textbook for an undergraduate process design course in a chemical or
petroleum engineering program. It can also serve as
a useful reference guide for practicing process engineers.
The authors have extensive experience in industry as well
as in teaching. The book is organized into ten chapters.
The first four chapters deal with basic material, including units and dimensions, stoichiometry, general process
engineering considerations, and process flowsheets. The
remaining chapters focus on the design of piping and
fluid-flow systems, heat exchangers, liquid-liquid extractors, distillation columns, absorbers and chemical reactors.
The chapter on the design of piping and fluid-flow sysBeltran_Wet Precipitators_Rev:Layout 1 12/6/07 4:55 PM
tems includes pressure-drop calculations through pipes,
valves, and fittings; design of pumps and compressors;
and the design of flow meters, including orifice plates and
rotameters. A very brief discussion on two-phase flow is
included as well.
The chapter on the design of heat exchangers is quite
extensive and includes shell-and-tube heat exchangers,
plate-and-frame heat exchangers, reboilers, vaporizers,
air-cooled heat exchangers and air heaters, heat-exchanger networks and energy integration.
The chapter on liquid-liquid extraction includes a
discussion of desirable solvent properties and selection,
design of counter-current multistage extraction units and
supercritical extraction.
Acid Mists
The design of distillation columns is the focus of the
next chapter, which includes a discussion of the McCabe SO3 Plumes
Thiele and Ponchon-Savarit methods for binary distil Submicron
lation and the Fenske-Underwood-Gilliland method for
Particulates
multicomponent distillation. More rigorous methods are
Opacity
also presented, including Lewis-Matheson, Thiele-Geddes
and equation-tearing procedures. There is considerable
Heavy Metals
discussion with regard to the design of trays and column
Enables the use
internals. Batch distillation, short-path distillation, reactive and catalytic distillation, and azeotropic distillation
of heavy oil/coal
are also presented.
instead of more
The chapter on absorbers includes the design of packed
expensive low-sulfur
towers, spray towers, and falling-film absorbers.
refined fuels.
The design of chemical reactors is presented in a chapter that focuses on batch reactors, continuous flow reactors, bubble columns and fixed catalyst beds. There is also
1133 East 35th Street
a section devoted to mixing.
Brooklyn, NY 11210
A particularly positive feature is the numerous detailed
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computational examples that are presented throughout
the book. Practical advice and examples of important in-
WET ELECTROSTATIC
PRECIPITATORS
Control
Emissions
From:
Chemical Engineering www.che.com January 2008
8-9 CHE 1-08.indd 8
12/26/07 1:53:42 PM
dustrial applications are also cited throughout the text.

Although briefly mentioned at various points, there is
no detailed information or coverage related to computeraided simulation, instrumentation and process control,
capital cost estimation or profitability analysis.
Batch Control Systems Design, Application, and Implementation. Second edition. By
William M. Hawkins and Thomas
Fisher. Elsevier, Radarweg 29, Amsterdam 1043 NX, Netherlands.
Web: elsevier.com. 2007. 336 pages.
Members: $95.00, non-members:
$99.00.
Biofuels. Edited by Lisbeth
Olsson. Springer, 233 Spring
Street, New York, NY 10013. Web:
springer.com. 2007. 368 pages.
$339.00.
Rules of Thumb for Maintenance and Reliability Engineers. By Ricky Smith and R.
Keith Mobley. Elsevier, Radarweg
29, Amsterdam 1043 NX, Netherlands. Web: elsevier.com. 2007. 336
pages. $95.00.
British Materials Handling
Board. By Tom Taylor. British
Materials Handling Board, 19
Chantry Avenue, Hartford, Northwich, Cheshire, CW8 1LZ. Web:
bmhb.co.uk. 2006. 20.00.
Process Engineering and Design Using Visual Basic. By
Arun K. Datta. CRC Press, 6000
Broken Sound Parkway, NW, Suite
300, Boca Raton, FL 33487. Web:
crcpress.com. 2007. 472 pages.
$129.95.
Applied Numerical Methods
with MATLAB for Engineers
and Scientists. By Steven C.
Chapra. McGraw Hill Education, 2 Penn Plaza, New York, NY
10121. Web: mche.com. 2008. 608
pages. $130.94.
Circle 11 on p. 58 or go to
adlinks.che.com/7368-11
Industrial Gases Processing.

Edited by Heinz-Wolfgang Haring.
Wiley, 111 River St., Hoboken, NJ.
Web: wiley.com. 2007. 310 pages.
$140.00.
n
Kate Torzewski
8-9 CHE 1-08.indd 9
12/26/07 1:54:10 PM
In the auto
industry, no one
drives faster
than Uniseal.
Uniseal is known throughout
the OEM auto industry as a
premier supplier of structural
adhesive and sealant systems.
With fast-moving R&D,
custom formulations and
superb quality, its easy to
see why this company has
been so successful.
To keep production in the
passing lane, Uniseal relies on
the finest equipment available
anywhere for high-viscosity vacuum
mixing: 10- to 1,500-gallon double
planetary and triple-shaft mixers
engineered right here at Ross.
Wed like to help you succeed, too.
Call 1-800-243-ROSS.
Or visit www.mixers.com.
Tom DiGiannurio,
Senior Engineer,
Ross Employee Owner
Edited by Gerald Ondrey
January 2008
Save space, money and water with

this new clarifier process
t Pollutec 2007 (Paris, France;

November 2730), Veolia Water
Solutions & Technologies (Paris,
edlinks.che.com/7368-531) introduced the next generation of its Actiflo clarifier process for potable and
process water Actiflo Turbo. Like
its predecessor, the patented Actiflo
Turbo process uses microsand to
enhance flocculation and settling,
which makes the process quicker
to startup, more stable in operation
and requires a smaller footprint, when compared to alternative processes. Flocculation
time is reduced to 3 min. and clarifier rise rate
is increased to 80 m/h, compared to up to 40min. flocculation time and 110 m/h rise rate
with traditional clarification, says the firm.
Actiflo Turbo features a Turbomixer reactor (diagram), which enhances the quality of
flocculation by avoiding dead zones and improving the homogeneous mixing in the flocculation tank. An additional feature of Actiflo
Turbo is the ability to thicken the sludge discharge up to 2%, thereby reducing water loss
to approximately 0.3% of the influent flow.

The first commercial application of Actiflo Turbo, currently under construction at
Clareville, Ireland, will produce 90-million
L/d of drinking water by mid 2008. The process can handle capacities in the range of 20
to 5,000 m3/h per single train. Investment
costs for an Actiflo Turbo facility (Clarevillesize) are said to be 10% lower for equipment
and 20% lower for construction than those
for the classic Actiflo process, and operating
costs are reduced by about 20% due to lower
energy consumption, says Veolia.
A new offshore GTL production system

takes advantage of microchannel reactors
oyo Engineering Corp. (TEC; Narashino,

Japan; edlinks.che.com/7368-532), Modec
Inc. (Tokyo, both Japan) and Velocys Inc.,
(Plain City, Ohio) have agreed to jointly
develop a commercial gas-to-liquid (GTL)
plant to be installed on a mobile platform
or ship for monetizing small-to-medium
sized natural gas fields. The project has the
potential to utilize more than 3,000-trillion
ft3 of natural gas that is now unexploited
because it is uneconomical to transport to
the world market. The group estimates that
the new technology could increase present
crude-oil production by 25% by utilizing
the natural gas that is currently flared at
crude-oil production sites.
The joint project involves a new GTL process using a microchannel-reactor system
for both steam reforming of natural gas and
Fisher-Tropsch (FT) synthesis. The reactor
features channels with 0.10.3-mm dimensions, compared to conventional reactors in
which the reactions are performed in 50
150-mm dia. tubes. The smaller dimensions
Note: For more information, circle the 3-digit number
on p. 58, or use the website designation.
enhance heat-transfer efficiency and increase the reaction speed, thereby improving productivity at lower capital costs, says
TEC. In addition, the new reactor system
can utilize a highly active catalysts with
tailored properties, says TEC.
TEC will design the GTL plant, based on
the microchannel reactor system developed
by Velocys, and Modec will construct a sea
vessel (platform or ship). A 50-bbl/d test
plant of the microreactor system is planned
for the U.S. in the near future. After the
confirmation test, the group plans to build
a 1,000-bbl/d commercial facility on a platform or ship in 2013.
Investment costs for a 1,000-bbl/d plant
are estimated to be about $73 million. The
total cost for the entire FPSO (floating,
processing, storage, and offloading) platform, including a 5,00015,000-bbl/d GTL
production plant, is estimated at $455910
million. The group expects the new system
will be profitable if future oil prices continue to be over $3040/bbl.
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C HEMENTATO R
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This CO2-recovery process

set to enhance EOR
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itsubishi Heavy Industries, Ltd. (MHI;

Tokyo, Japan; edlinks.che.com/7368533) is marketing a new process that captures carbon dioxide from flue gas (FG) for
enhanced oil recovery (EOR). The KM-CDR
process uses a proprietary amine-based solvent (KS-1) in a packed column to absorb
and regenerate CO2 with less energy than
conventional CO2-recovery processes and
with far less solvent loss, thereby reducing
the operating costs and increasing the efficiency of CO2 capture, says MHI.
The KM-CDR process was developed in
cooperation with Kansai Electric Power Co.
(Osaka, Japan; CE, January 2004. p.13), and
MHI has since delivered several commercial
plants to a variety of chemical companies
throughout the world. In 2005, MHI also established a strategic alliance with Shell EP
International Ltd. (Rijswijk, Netherlands)
to cooperate in the promotion of CO2 recovery from industrial sources for EOR projects
at oil fields in the Middle East.
By injecting pressurized CO2 into a reservoir (diagram), a supercritical phase, which
is miscible with oil, is formed. This decreases
the viscosity, and thus increases the flowability of the oil. MHI estimates that 10%
more of the original oil in place (OOIP) can
be recovered oil by EOR with CO2 (tertiary
EOP). Only 3040% of the OOIP is recov-
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etallic nanoparticles are usually produced by wet chemical methods, often

using toxic and flammable substances, or by
physical methods such as evaporation and
laser ablation. A group from the Laboratory
for Sustainable Technology, School of Chemical and Biomolecular Engineering, at the
University of Sydney (Australia; edlinks.
che.com/7368-534), has been experimenting
with the synthesis of nanoparticles of Cu,
Co, Zn, Ni, Ag and Au, within the cells of living plants which they call phytosynthesis. They achieved this by exposing Brassica
juncea (Indian mustard), Helianthus annus
(sunflower), and Medicago sativa (alfalfa) to
aqueous metal-salt solutions.
Group member Andrew Harris says they
showed, for the first time, that the size and
shape of the nanoparticles could be coarsely
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ered by conventional oil recovery methods,

which utilize the wells natural pressure
(primary recovery) or by pressurizing the
well with oil, water or gas (secondary EOR),
says MHI. The company expects to recover 4
bbl of oil per metric ton of CO2 injected, so
a 10,000-m.t./d KM-CDR plant operating at
a nearby natural-gas-fired power plant can
potentially recover 40,000 bbl/d of oil.
Presently, the amount of oil produced by
EOR is only about 0.3% of total oil production,
and most of the CO2 used is derived from gas
fields at a cost of about $2030/m.t. However,
the CO2 cost is expected to increase due to
limited availability. MHI says EOR projects
using CO2 captured by the KM-CDR process
will become feasible if the price of CO2 can be
linked with incremental oil recovery, say, $10
15 for the CO2 needed to recover 1 bbl/d of oil,
especially when oil prices stay above $40/bbl.
Using living plants to

synthesize metallic nanoparticles
$0
controlled by varying the plants growth conditions. The group soaked plant seeds in 5%
H2O2 for 15 min. (to avoid fungal contamination) and then washed them thrice with deionized water. The plants were grown under artificial light, for three to four weeks. The plants
were then transferred to Petri plates containing solutions of CoCO3, ZnCl2, CuSO4.5H2O,
Ni(NO3)2.6H2O, AgNO3, and KAuCl4.
B. juncea showed the greater ability to accumulate all of the metals investigated. With
all species, the greater the plant concentration
and substrate-metal concentration, the greater
the metal uptake. Also, the metals accumulated far more in the roots than in the shoots.
Ag was most readily accumulated, to a maximum of 9.2% on a dry weight basis, followed
by Au (5%), both with Indian mustard. Co was
the least extracted (1.5 wt.% maximum).
12$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
(Continued from p. 11)

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C HEMENTATO R
STORY NAME
Concentrated solar flux
This solar reactor will

recycle carbon dioxide
Set of counter-rotating rings

Reactive material
prototype solar reactor that will

break carbon dioxide into carbon
monoxide and oxygen, or split water Insulation
into hydrogen and oxygen, will be
started up this spring by researchers at Sandia National Laboratories
(Albuquerque, N.M.; edlinks.che.
com/7368-535). The ultimate goal
of the so-called Sunshine to Petrol
y
project is to recycle sequestered CO2
and combine the CO product with
z
H2 to synthesize liquid fuels.
The cylindrical reactor contains
14 alumina rings, 12-in. dia. by
1/2-in. thick, whose perimeters support 1in.-high monolithic segments of cobalt-substituted ferrite (COxFe3xO4). The disks
are arranged along a single axis, but two
motor-driven shafts rotate alternating disks
clockwise and the rest counter-clockwise, at
a rate of about 1 rpm.
In the upper part of the reactor the ferrite segments are heated to 1,4001,500C
by concentrated solar energy, via a quartz
window, causing the evolution of O2. However, by the time the heated section of a disk
rotates to the lower, dark side of the reactor, its temperature drops to about 1,100C.
This temperature is sufficient to break down
CO2 or split water, either of which is fed into
the bottom of the reactor, says Jim Miller, a
principal member of technical staff. Oxygen
O2
H 2O
y
x
method for the purification of singlewalled carbon nanotubes (SWNTs) in four

sequential steps oxidative pretreatment,
acid treatment, silica dissolution, and froth
flotation has been proposed by a team
from the Petroleum and Petrochemical College, Chulalongkorn University (Bangkok,
Thailand; edlinks.che.com/7368-536).
Team leader Sumaeth Chavadej says the
team used SWNTs synthesized from the
disproportionation of CO over Co-Mo/SiO2
catalyst. The SWNTs are first oxidized at
250C to convert the metal catalysts into
metal oxides, thereby increasing the exposure surface. After that, the oxidized
samples are treated with HCl where 90%
removal of the catalysts is achieved. In the
H 2O
x
H 2 , H 2O
released from either reaction re-oxidizes the

thermally reduced ferrite.
Normally, thermal breakdown of CO2
or water requires temperatures of well
above 2,000C, says Miller, but by dividing the reaction into two steps we can accomplish thermal splitting at much lower
temperatures. The cobalt helps by altering the thermodynamics of the reduction
step. Even more important, he adds, the
counter-rotation of the disks allows the
reduction and oxidation reactions to occur
simultaneously, at different temperatures,
while minimizing heat loss. In effect, says
Miller, we have a counter-current heat
exchanger that improves the maximum
potential thermodynamic efficiency from
about 35% to more than 70%.
Purification of single-walled nanotubes

using froth flotation
O2
silica dissolution step, NaOH is applied

to increase the carbon purity to 35% from
the original purity of 2.6%. Froth flotation
is then used to separate the SWNTs from
silica with two surfactants: sodium dodecyl
benzene sulfonate (SDBS) and alcohol ethoxylate surfonic L24-7.
SDBS provided the highest carbon purity, up to 69.3% at 0.5 critical micelle
concentration (CMC) and pH=5, compared
with 64.8% at 0.75 CMC and pH=7 for Surfonic L24-7. The team said under the optimum conditions with SDBS as a frother,
the four purification steps resulted in the
highest purity of total carbon at 70%, and
the physical structure of the SWNTs was
not damaged.
Bioethanol
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(Continues on p. 19)
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:13
C hementato R
Commercialization is set for a

Fischer-Tropsch process
entech, Inc. (Los Angeles, Calif.;

edlinks.che.com/7368-537)
will
build its first commercial synthetic
fuels plant, using the companys proprietary Fischer-Tropsch (FT) process,
near Natchez, Miss. The plant will gasify locally purchased petroleum coke or
barged-in coal, along with at least 5%
biomass. The resultant syngas of H2
and CO will be converted to straightchain waxy paraffins, which will be hydrotreated to obtain a combination of
sulfur-free diesel and jet fuels.
Rentechs F-T process uses an ironbased catalyst in a slurry-phase reactor to convert the syngas. An advantage of the process, says the company,
is that it can accept syngas with H2:
CO ratios ranging from 0.7:1 to 3:1. If
the excess of H2 is too high, the surplus can be recovered for use onsite.
In the projects first phase, scheduled
for startup in 2011 or earlier, the plant

will produce 1,600 bbl/d of fuels. An
additional 28,000 bbl/d of production
is planned for phase two.
Originally, Rentech had planned to
build its first commercial-scale reactor in East Dubuque, Ill., where the
company bought an ammonia-nitro-
gen fertilizer facility in 2006. The

plan was to convert the feedstock
from natural gas to coal, using gasification technology, and use excess gasification production for an FT reactor.
Rentech says it dropped that plan in
favor of the Natchez project because
of changed economics.
A fat shortage in 2008?

Animal and vegetable oils and fats are a key renewable feedstock for making
detergents, soaps, lubricants, paints, coatings, cosmetics and pharmaceuticals,
as well as additives for plastics, rubber and textiles. However, a consequence of
the current EU renewable-energy policy is leading to a significant threat to the
availability of these raw materials, which are now being burned to generate subsidized energy or used for biofuels, laments the European Oleochemicals and
Allied Products Group (APAG) of the European Chemical Industry Council (Cefic;
Brussels, Belgium). APAG says there is a growing concern that the European
oleochemical industry might not be able to meet customers demands in 2008 due
to shortage of raw materials.
11-15 CHE 1-08.indd 14
12/26/07 2:00:21 PM
Turning dishwashing
waste into fuel
Algae-to-fuel
iquid brown trap grease (LBTG), a

watery sludge recovered from dishwashing operations in restaurants,
will be the feed for the first commercial biodiesel plant of Bio Solutions Manufacturing, Inc. (BSLM, Las
Vegas, Nev.; edlinks.che.com/7368538). Scheduled for startup around
mid-2008, the plant will be designed
to produce 1.55 million gal/yr of B100
biodiesel fuel, says George McMahon,
vice president marketing. The plant
will be located in Elizabeth, N.J., and
operated by Fuel:Bio Holdings, LLC,
which already produces biodiesel fuel
from virgin vegetable oil at the site,
he says. BSLM will own the plant.
LBGT, a mixture of animal and vegetable grease and about 80% water, is
currently hauled to wastewater treatment plants, where it is dewatered and
burned. The key to BSLMs process,
Royal Dutch Shell Plc. (The Hague, Netherlands; edlinks.che.com/7368-544) and HR

Biopetroleum (Honolulu, Hawaii; edlinks.che.com/7368-545) have begun construction
of a pilot facility to grow marine algae, which will be harvested for producing vegetable
oil that will be converted into biofuel. The two partners have formed a joint-venture
company, called Cellana, to further develop the project. Located on the Kona coast
of Hawaii Island, the new facility is near commercial algae enterprises that primarily
serve the pharmaceutical and nutrition industries. It will grow natural marine microalgae species in open-air ponds using proprietary technology.
The advantage of algae over other crops is their rapid growth algae can double
their mass several times a day and produce at least 15 times more oil per hectare than
alternative crops, such as rape, palm soya or jatropha. Moreover, facilities can be built
on coastal land unsuitable for conventional agriculture, says Shell.
says McMahon, is the development of

a proprietary cleanup system to obtain a clean feedstock for conventional
biodiesel fuel production (using methanol and sodium hydroxide). The LBGT
is put into a holding tank, where food
particles fall to the bottom and grease
floats to the top. He declines to give full
details on the subsequent steps, except
to say that surfactants in the grease are
neutralized and animal and vegetable
fats are separated by centrifuge.

So far, the company has made fuel
in batches of less than 200 gal. McMahon notes that the advantage of the
process is that the feedstock is essentially free, whereas used cooking oil
sells for about $1.90/gal. He estimates
that B100 fuel can be produced at a
cost of $1.351.50/gal from a 1.52.5million-gal/yr plant, an appropriate
size for the process.
11-15 CHE 1-08.indd 15
12/26/07 2:00:57 PM
Newsfront
CPI CA
CAPITAL S
SPENDING
NG
OUTLOOK
FOR 2008 & 2009
ACCs chief economist says growth
will moderate in the near future
Thomas Kevin Swift
American Chemistry Council
t the beginning of 2008, its clear

that global economic growth is
slowing. The housing downturn
has adversely affected the U.S.,
and the ensuing credit problems (and
tightening) have spread to other nations. A key issue is whether or not the
weakness has done enough damage to
tip the economy toward recession. The
general consensus is that it is likely
that the U.S. will avoid a downturn but
experience a slowdown with concomitant and tentative sanguine prospects
for the broader global economy. Global
industrial activity will parallel these
trends, although an inventory correction may foster a stronger deceleration of factory activity. This will affect
global chemistry demand and as a result, growth will moderate into 2008.
Economic environment
The U.S. economy has clearly lost momentum, but despite the downturn in
housing, growth outside of housing
has been strong, driven by a surge in
exports and by resiliency in consumer
spending. The latter has been robust
as a result of sustained job creation
and strong income gains but growth
should slow in wake of negativewealth effects from falling home prices
and tighter credit. Any additional significant weakening of housing along
with a slowdown in job creation has
the potential to create the conditions
consistent with a recession scenario.
According to the International Mon-
etary Fund (IMF; Washington, D.C.),

world GDP (gross domestic product)
grew 5.4% (purchasing-power-parity
basis) in 2006, marking the best fouryear period since the early 1970s. Notwithstanding a pronounced slowdown
in the U.S., global growth of the last
few years will somewhat continue into
2008 and 2009, led by continued strong
economic growth in emerging markets.
With the powerful influence of globalization, world economic growth is anticipated in the consensus (or central)
scenario to average 4.6%/yr. Growth in
world trade appears to have peaked,
but will expand at a pace 1.5 times that
of output during 2008 and 2009.
Strong economic growth is anticipated in the Asia-Pacific region, as well
as emerging Europe. In addition, strong
commodity prices will aid growth in Africa and the Middle East and in Latin
America. Indeed, many emerging markets appear to be unaffected by the upheavals in the credit markets of North
America and Western Europe.
During 2007, year-over-year (Y/Y)
growth in global industrial production
has moderated, but it remains at a
high level. Capacity utilization is still
relatively high in many industries,
the consequence of low investment in
many industries during the past 10
years. Production in China and elsewhere in Asia-Pacific remains strong.
Leading indicators of global industrial
production suggest that the current
growth cycle has peaked and that the
global industrial cycle will shed momentum. It appears that another softpatch in global manufacturing is un-
16$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
derway, driven in part by an inventory

correction. This will cause growth to
slow. After a 6.2% gain in 2006, growth
in manufacturing activity will moderate in 2007 and into 2008 and 2009.
Major growth centers continue to be
China, other East Asia, and some Central and Eastern European nations.
In summary, although the U.S. economy has slowed, the consensus is that
a broad-based slowdown in economic
growth is expected but with enough
room to slow without slipping into recession. The global economy is rebalancing and economic growth should remain resilient, resulting in seven years
of relatively robust world economic
growth. This will provide an environment for the business of chemistry in
which production will continue to increase, albeit, at a diminished pace.
The risks, of course, are still quite
high and another, less-optimistic future for the economy is always possible. Eventually, economic cycles end
and the risks of a sharper more pronounced downturn are relatively high.
A pronounced global credit crunch is
the foremost risk at this point followed
by high oil prices. A hard landing in
China (a major economic locomotive)
is another threat as are ever present
financial market risks amid global
imbalances. Rising inflation could
lead to more aggressive tightening of
monetary policies in many nations,
setting the stage for weaker performance beyond 2008. Finally, the Avian
Flu, another major terrorist attack, or
other as yet unforeseen events could
dampen the global economy. There

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is no evidence that a recession has

begun, but the conditions are amenable for a recession scenario.
Business of chemistry outlook
During 2007, the global business of

chemistry has paralleled trends in
broader industry, and overall activity
in the $2.85-trillion global business
of chemistry has moderated as well.
Gains during the past year have been
broad-based but largest in China, elsewhere in Asia-Pacific, in Africa and
the Middle East, and in Central and
Eastern Europe. The global chemical
industry still appears to be in an expansionary mode but one consistent
with a more-mature phase of the cycle.
Leading indicators of global industrial
production continue to suggest that the
growth cycle peaked. Moreover, recent
softness reflects some downstream inventory de-stocking in many nations.
In addition, capacity additions in the
Middle East have moderated as many
projects have been delayed.
Global business of chemistry output
will increase 4.2% in 2007, down from
the peak 5.2% gain in 2004. Growth
will improve to 4.4% in 2008 before
moderating to a 4.1% gain in 2009.
During the next two years, the most
rapid growth will occur in the emerging nations of Asia-Pacific, Africa and
the Middle East, Central and Eastern
Europe, and Latin America. Most notable are China, India, and Russia but
Korea, Singapore and Taiwan will also
present good growth prospects through
2009. Among the developed nations,
Ireland and Germany will experience
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the strongest growth. Elsewhere, the

prospects will be more muted. Only
nominal growth is expected in the U.S.
and Japan. Italy and Sweden will see
declines this year with recovery in
2008 and 2009.
For the $637-billion business of
chemistry in the U.S., a slowdown in
manufacturing emanating from light
vehicles and housing-related industries
(construction goods, appliances, furniture, carpeting and so on) engendered a
modest downstream inventory correction during 2007. By the 3rd quarter,
demand and supply was again in balance and the industry posted strengthening year-earlier comparisons.
The U.S. business of chemistry faces
some economic headwinds. A major
risk at this point in the cycle is volatile natural-gas costs. Although costs
are off from their post-hurricane highs
and down relative to oil, long-term
supply-demand imbalances remain.
A comprehensive U.S. energy policy
ensuring adequate and diverse supply
including that from outer continental shelf (OCS) and other new areas
would go far in moderating volatility
and supporting the competitive position of U.S. industry and maintaining
the value-added benefit that chemistry provides to the economy.
With a weak start to the year, the
U.S. business of chemistry will experience a gain of 0.4% during 2007. Pharmaceuticals took over as the growth
leader and will gain 1.2% this year.
Excluding pharmaceuticals, slippage
will actually occur for the year as a
whole. Strong growth is anticipated
Bioengineering
Inversina
the gentle way
of mixing.
The Inversina mixes solids or liquids
thoroughly and efficiently. The process
is clean, because mixing takes place in
closed containers that can be quickly
interchanged. The Inversina mixes a
diverse range of components rapidly
and in an extremely gentle way.
Segregation does not occur, even
after extended mixing times, by virtue
of the eversion phenomenon ( Paul
Schatz principle ) .
Applications for the Inversina: analytical labs, metal finishing shops, powder
metallurgy and nuclear industry,
manufacture of batteries, cement,
ceramics, cosmetics, dental products,
diamond tools, dyes and pigments,
electrical and electronic devices,
explosives and pyrotechnics, foods,
homeopathic products, household
products, medicines and pharmaceuticals, plastics, printing inks and many
other products. The Bioengineering
Inversina is available with capacities
of 2, 20, 50, 100 and 300 L .
Bioengineering, Inc.
Waltham, MA 02451, USA
Bioengineering AG
8636 Wald, Switzerland
info@bioengineering.ch
www.bioengineering.ch
64#VTJOFTTPG$IFNJTUSZ$BQJUBMTQFOEJOH

high capital costs reflect

the large-plant capac
ity often needed to ob

tain economies of scale

in producing chemicals,

:FBS
the intricate nature of
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the equipment and processes used, the large
Figure 3. Substantially more is invested today than a
amounts of equipment decade ago
needed, the high level
of technology required, and the rapid capital stock that is available to each
technological obsolescence and depre- worker. Increasing levels of capital emciation of process plants. Indeed, the ployed per worker (also called capital
level of net property, plant and equip- deepening) have long been noted as a
ment (a proxy for capital stocks) per key to improved productivity, indicatemployee in the business of chemis- ing that workers are equipped with the
try is nearly three times that for U.S. latest technological innovations that
manufacturing as a whole.
are embodied in the acquisition of new
Capital intensity (or capital em- capital (and capacity). Higher producployed per worker) is a good indicator tivity is in turn typically accompanied
Capital spending dynamics
of the adequacy of capital formation. by higher real wages for workers.
The nature of the business of chem- Changes in capital formation and
A number of factors drive the magistry, which lends itself to a high de- employment growth show up in what nitude and composition of investment
gree of automation, engenders pro- economists refer to as capital endow- in new plants and equipment, which is
digious capital requirements. These ment that is, the average amount of also referred to as capital investment
or capital spending. One of the major
determinants is the level of profits. Capacity utilization measures the extent
to which the capital stock of an industry is being employed in the production of goods. It rises and falls with the
business cycle. Historically, there is a
positive relationship between the capacity utilization rate and subsequent
capital spending. High rates of capacity utilization beget rising levels of
capital spending. In addition to profits
and capacity utilization, other factors
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Capital investment is composed
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Buildings and structures accounted
1FSDFOUDIBOHF
this year in synthetic rubber as well

as in bulk petrochemicals and organic
intermediates. Plastic resins and
some specialty chemical segments will
experience more nominal growth with
weakness centered elsewhere. Segments tied to housing, light vehicles,
furniture and appliances in particular
will face challenges.
Assuming the consensus economic
environment, overall U.S. chemical industry growth will improve to 1.8% in
2008 and then 2.2% in 2009. A more
mature stage of the chemicals will
characterize these years as will strong
export volumes. In 2008, basic chemicals and specialties will strengthen.
Basic chemicals will strengthen even
further in 2009.

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Newsfront

Emissions Compliance
Through Catalyst Innovation,
Experience & Nanotechnology
18
16-20 CHE 1-08.indd 18
12/26/07 1:45:47 PM
T-0630 4 Product
for the remaining 25% of the balance

The equipment category is composed
primarily of such traditional process
equipment as: fabricated metal products (pressure vessels, storage tanks,
heat exchangers, pipe, and so on); general-industry machinery (pumps, compressors and so on); electrical transmission, distribution, and industrial
apparatus; and other special industry
machinery. With expansion of capacity
for existing and new products serving as a motivation for spending, expenditures for this traditional process
equipment has been strong. Indeed,
deliveries have generally lengthened
for many of these types of equipment
as worldwide ability to fabricate and
manufacture has been limited.
A sizable portion of equipment
spending in the business of chemistry
is for instrumentation, computers, and
related automation (or informationprocessing) technologies. Expenditures
for these technologies has been strong
as well, but this category also does well
during periods of soft capital spending,
when projects for improving operating
efficiencies predominate. Less than
5% of total capital investment is typically spent on furniture, automobiles,
trucks and truck trailers, and other
non-process related equipment.
To a large degree, the purpose for
structures in the business of chemistry is largely to protect chemical
processes from the elements and to
support process equipment. Investment in structures is mostly for industrial buildings and related structures (loading docks, terminals and
so on) but also includes some minor
spending for office buildings. With capacity as a motivation for investment,
spending for building and structures
has been strong recently. This is particularly the case in the Middle East.
Capital spending outlook
Worldwide capital spending by the

business of chemistry increased
steadily through the early 1990s to a
crest of $125 billion in 1997, before falling for several years as Asian companies pulled back on spending in wake
of the crisis in that region as well as
a recession in 2001, diminished expectations, over-capacity in some areas,
the negative impact of consolidation,
16-20 CHE 1-08.indd 19
and other factors. This pushed spending down to a trough of $112 billion in
2001, an overall decline of 10%. Since
then, spending has surged, increasing
71%, with the global business of chemistry investing $191 billion in new
plant and equipment (P&E) during
2006. The data presented in the chart
are presented for the first time to the
public. ACC does not adjust its historical figures for inflation to attempt constant dollar comparisons, but backof-the-envelope calculations show
substantially more is invested today
than a decade ago.
Capacity utilization rates are relatively good as are profit margins in
much of the world. Additional growth
in demand is expected and the cost
of credit is still modest. In addition,
availability of credit does not appear
to be a problem. As a result, the global
outlook for spending is positive. As
the current investment cycle further
matures, capital spending will increase 15.5% to $223 billion in 2007.
Given announced projects and industry dynamics, the global investment
cycle will continue, with additional
strong but maturing growth prospects. Global capital spending by the
business of chemistry is expected to
increase 14.8% to $256 billion in 2008
and decelerate, increasing only 12.3%
to $284 billion in 2009. Prospects beyond 2009 are less certain.
The bulk of the additional investment will arise in the Asia-Pacific
region, which will account for 58% of
the incremental gain during the 2006
to 2009 period. Africa and the Middle
East will account for nearly 15% of the
incremental gain. The developed nations of North America and Western
Europe will account for less.
Turning to the U.S., the accompanying chart (Figure 1) illustrates that the
past peak in capital spending occurred
in 1996. The worst business conditions in a generation led to a difficult
environment for capital spending by
the business of chemistry, especially
during the 2000 through 2003 period.
Lingering uncertainty concerning future demand combined with volatile
feedstock and other energy costs hindered capital investment. As a result,
sustaining capital played a large role
earlier this decade, and for a number
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of years capital spending was actually
below depreciation levels.
Capital spending cycles generally
lag cycles of industry activity. Improved profit margins set the stage for
moderate increases in new plant and
equipment (P&E) investment. Improving capacity utilization rates could
trigger renewed capital spending by
the industry. Spending increased 6.5%

to $22.5 billion in 2006. As the current investment cycle further enfolds,
capital spending will increase 6.0%
to $23.8 billion in 2007 and then increase 6.3% to $25.3 billion in 2008.
At that point, the previous 1996 peak
in capital spending will be breached. A
further 6.0% gain in spending to $26.8
billion is anticipated in 2009.

The largest proportion of capital
spending is allocated towards expansion of production capacity and
replacement of worn out plant/equipment. Furthermore, the majority of
the expansion of production capacity is for the existing product range.
New products are less important. Increased spending for expanding production capacity for existing products
is a driver, particularly for the specialty chemical companies.
Of great interest is the ongoing geographical shift in spending by U.S.
chemical companies. With a mature
market and the movement of customer industries overseas, companies
are shifting investments toward regions offering lower feedstock costs
(and cost of production) as well as in
markets experiencing a higher degree
of dynamism. The absence of a comprehensive U.S.-energy policy ensuring adequate and diverse supplies will
retard investment (and subsequent
job creation). This is equivalent to
capital flight. The geographic allocation of the capital budgets of responding companies is evidence of this shift.
U.S. chemical companies expect to
reduce their U.S. share of their total
capital spending budgets from 62% in
2006 to 48% in 2011. They anticipate
significantly boosting their share to
Africa and the Middle East, from 2%
in 2006 to 15% in 2011. Global capital
spending patterns presented previously clearly reflect this ongoing shift.
Summary
Continued economic momentum will

foster a global environment conducive
to expanding business of chemistry activity. Gains in worldwide volumes will
continue into 2008 and 2009. The risks
of course are high and prospects beyond
2009 are less certain. Nonetheless,
given announced projects and industry
dynamics, the global investment cycle
will continue, with additional strong
but maturing growth prospects. Global
capital spending by the business of
chemistry will reach new highs.
Author
20
Thomas Kevin Swift is the chief economist at

the American Chemistry Council (ACC; 1300
Wilson Blvd., Arlington, Va. 22209; Phone: 703741-5932; Fax: 703-741-6085; Email: kevin_
swift@americanchemistry.com).
16-20 CHE 1-08.indd 20
12/26/07 1:47:09 PM
Newsfront
CLEANING UP WITH
CATALYSTS
As worldwide regulations grow more
stringent, catalyst development focuses
on providing cleaner energy sources and
cleaning up air pollution
s long as the chemical process

industries (CPI) have existed,
catalysts have been backstage
supporting, if not leading,
their progress. And, as much of the
chemical industrys current research
efforts center around producing
cleaner products, such as transportation fuels and energy sources in
a greener way, the same can be said
about catalyst development.
Certainly, a major reason for the
clean and green focus is tightening
regulations surrounding fuels and air
pollution, which have resulted in an
upswing in the demand for catalysts
developed for these applications.
A variety of factors have made
oil refining catalysts the sector to be
in, says Tony Pavone, senior project
manager with SRI Consulting (Menlo
Park, Calif.). Zeolite catalysts for
fluid-catalytic cracking (FCC) and
hydro-cracking and base metal hydrogenation catalysts, such as nickel,
cobalt and molybdenum, used primarily for desulfurization, are enjoying a
renaissance, he says.
The demand for clean, refined
products, such as gasoline, jet and
diesel fuels, is growing twice as fast
as crude oil in general, requiring refiners to upgrade the bottom of the
barrel through catalyst processes
rather than selling black fuels such
as asphalt and heavy fuel oil.
Resid hydro-cracking and resid FCC,
both of which require hydrogenating the
resid, are growing, compared to purely
thermal processes such as delayed coking, vis-breaking and solvent extraction.

Pavone adds that requirements for
extremely low sulfur content in clean
fuels has dramatically increased the
need both for catalysts used in fuel
de-sulfurization and syngas catalysts
used to produce the necessary hydrogen. Refinery hydrogen demand is
increasing by over 10% per year, with
these growth numbers representing
volume, not price, he says.
Likewise, as air emission regulations around the world tighten, effective air-pollution-control catalysts
are being sought, especially those
for NOx control in the U.S., Asia and
Europe, according to Bob McIlvaine,
president of McIlvaine Co. (Northfield, Ill.). The world market for catalysts for NOx control will grow from
$610 million this year to over a billion in 2011, he says. Theres a huge
market for catalysts that clean up
power plant stacks. The U.S. is halfway there, but the Asian countries
are just getting started, which will
result in the predicted growth.
And, as quickly as end users are
purchasing these types of catalysts,
researchers are just as frantically
working to develop improved versions or entirely new technologies to
meet the demand.
Cleaner fuels and energy
A dramatic increase of crude oil

prices, environmental concerns and
the desire to be less dependent on
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imports have greatly elevated the interest in alternative energy sources

over the past few years. There is little
doubt, says Yvonne Zhang, catalysts
division marketing manager with
Sud-Chemie (Munich, Germany),
that a substantial share of world
energy has to come from alternative
sources in the mid to long term due
to increasing global oil consumption
and a dwindling oil reserve.
She notes that fossil energy carriers, such as natural gas and coal, could
be used as alternative feedstocks to
produce transportation fuels using
Fischer-Tropsch synthesis. These
synfuel products have the advantage
of containing essentially no sulfur or
nitrogen compounds, making them
ideal for blending to meet increasingly
stringent fuel standards.
In addition, biofuels and other forms
of renewable energy aim to be carbon
neutral. This means that any carbon
released during the use of the fuel is
reabsorbed and balanced by the carbon
absorbed by new plant growth, says
Zhang. So, producing transportation
fuel from biomass feedstock (BTL) is
considered an important means of reducing CO2 emissions and increasing
energy security while providing an alternative to fossil fuels.
Current BTL technologies under development include bio-DME, FischerTropsch diesel, bio-hydrogen, bio-methanol and mixed-alcohol production.
Many of these processes involve the
production of syngas as the first step,
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:21
Newsfront
MEAN, GREEN AND CLEAN
s part of a practice that aims to prevent waste rather than

treat or clean it up after it has been created, researchers at
the Green Chemistry Institute of the American Chemical Society (Washington, D.C.) and Carnegie Mellon Universitys Institute
for Green Oxidation Chemistry (Pittsburgh, Pa.) have developed
a group of designer catalyst molecules called tetra-amido macrocyclic ligands (TAMLs), which are activators that work with
hydrogen peroxide and/or other oxidants to break down many
pollutants, according to Terrence Collins, a Thomas Lord Professor
of Chemistry at Carnegie Mellon University and director of the
Institute for Green Oxidation Chemistry.
The catalysts, which mimic the enzymes in the human body that
fight toxins, have been found in both lab and real-world trials,
to effectively destroy pesticides, dyes and other contaminants,
decrease smells and stains from the wastewater discharged by
paper mills and kill bacterial spores.
Developmental work on the catalysts began in the 1980s when
concerns about the safety of using chlorine as a cleaning and disinfecting agent came into focus. Rather than relying on chlorine,
we wondered if we could use hydrogen peroxide and oxygen to
tackle pollution, says Collins. These cleaners safely clean up
many pollutants, but in nature the process usually requires an
enzyme a biochemical catalyst that increases the rate
of the reaction.
Developing the synthetic enzymes required
the assembly of molecules that would be
able to stand up against the destructive
reactions they were catalyzing. Any
chemistry involving oxygen can be
destructive because the bonds it
makes with hydrogen and other
elements are very strong, says Collins. And, because each molecule
of hydrogen peroxide is half way
which is where catalyst development plays a role. Firms like

Sud-Chemie have been busily researching and developing catalysts
with the goal of providing solutions
for feedstock purification and syngas
production. New product generations as well as unique Sud-Chemie
catalysts for syngas conversion have
been added to our product portfolio,
says Zhang.
Such products from Sud-Chemie
include MegaMax methanol synthesis catalyst for Lurgi AGs (Frankfurt,
Germany) MegaMethanol process and
zeolite-based MTRPOP catalyst for
Lurgis MTP process.
Sud-Chemie is not alone in this pursuit. Firms like BASF Catalysts LLC
(Iselin, N.J.) are also looking at catalysts to help green up energy sources.
Biorenewable energy sources, energy
frugal catalytic processes and hydro-
between water and molecular oxygen, this compound is also

strongly oxidizing.
In water, hydrogen peroxide can produce a kind of liquid fire
that decimates the organic molecules around it, which means that
a working catalyst would need to have an iron atom placed inside
a molecular matrix of organic groups. We had to strengthen the
molecular architecture of these groups to ensure that they would
survive the liquid fire that would result when activating the hydrogen peroxide, explains Collins.
After a fifteen-year research and development period, the first
successful, working TAML was created, and since then, roughly
20 different TAML activators have been developed, each with a
unique reaction rate and lifetime, allowing catalysts to be tailored
to specific tasks.
Some are designed to seek out and lock onto specific pollutants
or pathogens, others aggressively burn most of the oxidizable
chemicals they encounter, and still others attack only certain parts
of molecules or only more easily oxidizable molecules.
We expect to use TAMLs to advance green chemistry far into the
future, says Collins. And while he notes that more toxicity testing
must be done, the results show that they effectively breakdown
pollutants and leave no detectable contamination behind. Potential applications for the technology include water purifi
purification, desulfurization of diesel, a defense against
biological warfare, getting rid of smells and
colors from pulp and paper manufacturing
and even simple laundry powders.
The object of our research was to use
these catalysts with peroxide to replace
chlorine processes in cleaning, water
purification and heavy metal oxidation, so they may have applications
in all these areas and then some,
says Collins.
P
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PGPOFPG(SBDF%BWJTPOhTGMVJEDBUB
MZUJDDSBDLJOHDBUBMZTUT
gen-based fuel cell systems all require

novel heterogeneous catalysts based on
nanoparticulate dispersions of precious
and base metals on metal supports,
explains Robert Ianniello, director of
research and development with BASF
Catalysts Chemicals, Polymerization
and Refining Catalysis group.
He too provides the example of the
conversion of biomass (think cellulose
and carbohydrates) to hydrogen and/
or syngas and says in this technology,
22$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
the process takes place in an aque

aqueous solution under moderate tem
temperatures and pressures. Such an
approach alleviates the need for using
high pressures and temperatures and
organic solvents, thus representing an
environmentally friendly way of mak
making a cleaner energy source.
Other firms, such as Haldor Tospe
(Houston, Tex.) are focusing on helping refineries generate cleaner burning transportation fuels out of more
difficult crude. The new specs for
gasoline in the U.S. are 30-ppm sulfur,
says Henrik Rasmussen, vice president, catalysts and technology sales.
To achieve these levels when processing heavier crude slates, you need better catalysts and new technologies.
He notes that this is becoming increasingly important as the reserves
of sweet (low-sulfur) crude are running out. To help combat the problem,
Topse specializes in
(Columbia, Md.). By
Catalysts technology providers
building new facilities
reducing the end point
Albemarle
edlinks.che.com/7368-591
with the latest technoloof the gasoline, they are
BASF Catalysts
gies and catalysts necesgiving up volume. But if
Bayer
sary to allow refineries
we can reduce the gasoDuPont
to process these crudes.
line sulfur with catalysts
Haldor-Topse
And because the cataor additives and allow
Institute for Green Oxidation Chemistry
lysts feature improved
refiners to avoid underJohnson Matthey
catalyst activities, refincutting, it will increase
Sd-Chemie Group
eries can run long cycles
their yield of gasoline.
W.R. Grace
even with lower-quality
Similarly, Topse is
crude, explains Rasdeveloping new generamussen.
for producing cleaner transportation tions of catalysts that enable refiners
New formulations for this applica- fuels, but they also allow refiners to to make more money by processing
tion include high activities for certain get more product a plus during the more barrels of crude. Rasmussen
reactions that are beneficial when current refinery crunch.
says that Topse has optimized the
running low-quality crude. When
As a result of sulfur reductions, active sites on its catalysts, which
you run these difficult crudes, you many refiners are undercutting, or helps generate clean fuels more efalso have problems with octanes in reducing the end point of the gasoline ficiently. Using Topses BRIM techgasoline and cetanes in diesel, he because the sulfur is found in this nology, refiners are able to put about
says. These new catalysts offer good heavier boiling range of gasoline frac- 94% of the barrel into jet, diesel or
conversions of the components that tions, says Joanne Deady, vice presi- gasoline engines. This means that
provide more desirable octane and dent, marketing/research and devel- not only is more being produced, but
cetane levels.
opment with Grace Davison Refining less is going to waste as sulfur and
Chem_Eng1-1_177x123_Januar08
07.12.2007
11:33 division
Uhr Seite
1
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23
12/26/07 1:30:35 PM
Newsfront
Todays refiners have coking technology, which helps squeeze the last
drop of transportation fuel from the
bottom of the barrel, explains Rasmussen. In the old days the stuff at
the bottom was turned into asphalt,
but now refiners can go through it
one more time and get more fuels out
of it. Fuel production is cleaner and
more efficient today than it was years
ago due to new catalyst technologies.
Air-pollution control
There are probably more catalytic approaches to air-pollution control than

there are pollutants in need of control.
And as air-emission regulations grow
more stringent, even more catalysts
are being developed. For instance,
BASF is focusing on the use of heterogeneous catalytic materials. One
method focuses on additives used in
FCC processes to catalytically convert
the oxides of sulfur and nitrogen as
"IZESPQSPDFTTJOHDBUBMZTUGSPN(SBDF
%BWJTPOJTEFQJDUFEIFSF
well as carbon monoxide to inert materials, says Ianniello.

Grace is also tackling the issue of
NOx from FCC units via the use of
new low-NOx combustion promoters.
Traditional combustion promoters
have been platinum based, which
tends to increase NOx, so weve moved
away from this material as a combustion promoter in our formulations,
explains Deady. She says Grace also
developed stand-alone additives de-
signed to reduce NOx, which work

as a very complex mechanism in
the FCC generator.
Also concerning air pollution,
BASF is examining the generation
of synthesis gas (a key raw material
for Fischer-Tropsch processes) from
carbon dioxide to methane (so-called
dry reforming) using rhodium-based
catalysts as an interesting alterna
alternative to CO2 deep-well injection, according to Ianniello.
He adds that BASF is working towards the development of new photocatalytic materials based on modified
titanium dioxide for the decomposition of volatile organic compounds in
indoor air.
When it comes to using catalysts
in air-pollution control applications,
new developments stem from working
with different chemistry and different units and trying to find out what
works best, says Deady.
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Newsfront
call for nominations
Personal Achievement Award
t is likely that in your work,

you have crossed paths with a
person you admire for a career
involving excellence in chemical engineering. If you would like to
recognize this individuals accomplishments, nominate him or her for
our 2008 Award for Personal Achievement in Chemical Engineering.
The aim of this award, which
Chemical Engineering has offered
biennially since 1968, is to honor individuals for distinguished careers.
It complements CEs Kirkpatrick
Chemical Engineering Achievement
Award, presented in the alternate
years, which honors companies for
specific chemical-process accomplishments (see December, p. 19).
Our Personal Achievement awards
have saluted excellence in diverse
areas research, development, design, plant operations, management
and other activities. The distinction
can emerge in less-ordinary ways,
such as government service. The criterion is that the career must have
related, fully or largely, to the use
of chemical engineering principles
in solving industrial, community or
other problems.
Its easy to nominate
Submitting an award nomination is a

simple matter:
1. State the name, job title, employer
and address of the candidate.
2. Prepare a summary, in up to about
some RECENT WINNERS
Help us honor distinguished careers

in chemical engineering.
The process is both easy and gratifying
500 words, that highlights your
nominees career and brings out his
or her creativity and general excellence in the practice of chemical engineering technology. At least some
of the activity must have taken place
during the three-year period ending
Dec. 31, 2007. Be specific about key
contributions or achievements. But
do not include confidential information in your writeup.
3. Please be sure to include your own
name and address, in case we need
to contact you.
4. Send your nomination no later than
April 15 to:
Personal Achievement Award Secretary
Chemical Engineering
110 William St., 11th floor
New York, NY 10038
Email: awards@che.com
We encourage you to ask others to
provide information in support of the
nominee; ask them to write to us by
April 15. Such input has often proved
to be decisive during the judging.
Whats next
Once we receive a nomination, we

will ask the candidate whether he or
she is willing to be considered (you
may instead do so yourself). Mean-
while, we might take any steps that

seem called for to verify the accomplishments stated in the brief or the
supporting letters.
Next, we will send all the nominations to a panel of senior chemical engineering educators, who will evaluate
and rank them. Based on the voting of
these judges, we will designate one or
more winners. Then we will inform all
the nominees and nominators about
the results of the voting.
An article in Chemical Engineering
around the end of this year will profile
the winners. Around the same time, we
will present awards to these persons.
Points to keep in mind
Nominees can be from any country. They need not hold a degree
in chemical engineering. But their
achievements must have involved
use of chemical-engineering principles in solving problems, and part
of the activity must have been in
20052007.
The Personal Achievement Award
has been hailed and respected since
its inception. We welcome your nomination, to help us maintain this worthwhile activity.
Rebekkah Marshall
When thinking about whom to nominate, keep in mind that a distinguished career
can take many forms. Here, for instance, are the most recent winners:
Lawrence B. Evans has been Henry Kister, of Fluor, has Michael Lockett, of Praxair, John Pelton, also of Praxair,
cited for his leadership in devel- been hailed as the world's whose career has involved who spent over six decades
oping and applying integrated foremost authority on distilla- academe as well as industry, in industry, was the driving
systems for modeling, simulation and absorption trouble- may be best known for his de- force behind innovations in
tion and optimization of chemi- shooting. He has written two velopment of new distillation such fields as crystal formacal processes. After early years widely consulted engineering and heat-transfer technolo- tion and growth, high-temas a chemical engineering pro- books on distillation, as well as gies. Correlations and papers perature flame-coating, confessor at M.I.T., he devoted the over 70 articles, and has taught of his on distillation-tray ef- version of waste to fuel gas,
bulk of his career to founding courses and spearheaded sym- ficiency long have been stan- and aluminum refining
and leading AspenTech

posia in distillation
dard references
25 CHE 1-08.indd 25
25
12/27/07 1:38:09 PM
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Carbon steel, stainless steel, nickel and alloy bodies
Gland plate adjustable without removing actuator
Meets all latest industrial codes and standards
NPT, socket weld and buttweld end connections
Rugged RPTFE spiral wound body seals
Fully machined ISO 5211 mounting
Cast purge and drain bosses
Two-position locking device
American-made Apollo Class

600 full-port industrial ball
valves give you superior
quality, performance and
more standard features for
long, reliable service in tough
applications like power, pulp
and paper, oil field, refinery
and chemical processing.
COAP 0243-09
For real American values,

always trust Apollo Valves.
MADE IN THE USA
Co nway, S C
26 CHE 1-08.indd 26
M a tt h ews, N C
Pa g e l a n d , S C Cu sto m e r Se r v i ce 1 -70 4- 8 41 - 6 0 0 0 w w w. a p o l l o 3 p c b a l l va l ve.co m

12/20/07 6:45:00 PM
Sedimentation
Centrifuging
Department Editor: Kate Torzewski
entrifugation is the method of choice

in the chemical process industries (CPI)
for separating solids from liquids. It
relies on the G-forces generated by highspeed rotation to recover solids or liquids
from slurries, as well as clarify liquids or
classify solids.
Centrifuges can be categorized as either
sedimentation or filtration units. Sedimentation centrifugation relies on a difference in
density between the solid and liquid being
separated. Filtering is performed with a
rotating basket fitted with a filter medium,
where the centrifugal force of rotation
expels the liquid through the filter.
basics of Sedimentation
Centrifuging
The mechanics of sedimentation centrifuging make it ideal for two-phase systems
with a high-density differential. As an
incoming slurry spins in a sedimentation
centrifuge, it forms an annulus adjacent to
the bowl wall. The centrifugal force causes
the denser material to move outwardly toward the wall of the centrifuge bowl, while
the liquid overflows from the bowl or is
picked up by a skimmer. Periodically, the

solid must be removed from the centrifuge
manually or with a cutter knife. Alternatively, it can be removed continuously with
a screw conveyor. Sedimentation centrifugation allows material to be separated
hundreds or thousands of times faster than
simple sedimentation by gravity alone.
Stokes Law tells us that settling velocity

can be maximized with a high centrifugal
speed, large particle size, large density
difference between solids and liquid, large
separation radius and low liquid viscosity.
applications
According to Stokes Law, the terminal

velocity of a particle is determined by the
centrifugal gravity (2r) created by the
centrifuge with particle-balancing buoyancy and viscous drag taken into account.
This terminal (settling) velocity is determined by the equation below:
Centrifuge selection is heavily dependent

on characteristics of the incoming slurry, including particle size, solids concentration,
liquid viscosity and density differential. Other factors that come into play are the need
to remove solids periodically or continuously and the degree of purity required of the
separated products. Table 1 summarizes
the mechanics and suitable applications of
common sedimentation centrifuges.
Vs
References
stoKes' law
1
7 2r ( R s R L ) d 2
18 M
where
Vs = Settling velocity, m/s
= viscosity, kg/ms
= angular speed of rotation, rev/min
s = density of solid, kg/m3
L = density of liquid, kg/m3
d = particle diameter, m
r = centrifuge radius of curvature, m
1.Scroder, T. Selecting The Right Centrifuge, Chem.

Eng. September 1998, pp. 8288.
2.Moir, D. N. Sedimentation Centrifuges: Know What
You Need, Chem. Eng. March 1988, pp. 4251.
3.Bershad, B. C., Chaffiotte, R. M., Leung, W. F.
Making Centrifugation Work For You, Chem.
Eng. August 1990, pp. 8489.
4.Perrys Chemical Engineers Handbook, 8th ed.
New York: McGraw Hill, 2008.
TABLE 1. types of sedimentation centrifuges
Type
Mechanics
Best suited for
Tubular
Bowl
Purification of lubricating
A
vertical cylinder with the feed
The heavier phase becomes concenslurry introduced in the bottom of
trated against the wall, while the lighter
and industrial oils
the bowl
phase floats on top
Food, biochemical and
The use of a distributor and baffle The two phases are separated by a baffle
pharmaceutical applications
assembly accelerates the slurry to Liquid discharges over the top of the bowl, Solids should be less than 1%
the speed of rotation
while solid buildup is removed manually
in volume of the slurry
Multichamber
C
onstructed of a series of tubular
sections arranged concentrically
The slurry feed enters in the
smallest tube and continues
through the outer tubes as they
increase in size
L arger solid particles settle in the small

tubes, and particles of smaller sizes settle
in subsequent tubes
Up to six chambers are typical with a
maximum holding capacity of 0.064 m3
Skimmer
Feed enters the hub end and
When a thick solid layer begins to form
pipe /
is accelerated to speed before
on the bowl wall, supernatent liquid is
knife
entering the separation pool
removed with a skimmer, and solids are
discharge Solids settle on the bowl wall while
knifed out with centrifugal filters
liquid overflows the ring weir
C
larifying fruit juices, wort
and beer
H
eavy-duty applications,
such as coal dewatering
Disc
Solids settle under the disc and move

Self-cleaning types:
F eed enters through the top axis
of the bowl and is accelerated by
downward to be released at the bottom of purification of beverages,
a radial-vane assembly
the bowl wall
mineral oils, and edible oils
The unit is constructed of a stack Liquids travel up the conical channel,
Disc nozzle: corn wet
of typically 50 to 150 closely
and their upward movement in the
milling (starch separation,
spaced conical discs arranged at
centrifuge is facilitated by holes across
gluten thickening), clay
an angle between 40 and 50 deg
each disc
classification, acid crystal
washing, lube oil dewaxing
Decanter
S
olids are removed from the conical
Applications that require
discharge end (the beach)
continuous removal of solids,
where feed solids are high
Bowl and conveyor rotate in the same
and volume reduction is
direction, but at different speeds, creating
important
a speed differential that controls the
speed of solid removal
A solid bowl decanter with a cylindrical screen added to the conical end
Improved cake dryness and
highest product purity
Screenbowl
27 CHE 1-08.indd 27
C
onstructed of a solid external
bowl and an internal screw
conveyor mounted horizontally
1/2/08 11:22:33 AM
People
WHOS WHO
Berendsen
Geisel
Thomas H. Lane is named presidentelect and will serve as president in

2009 for the American Chemical
Society (Washington, D.C.).
Calvalley Petroleum, Inc. (Calgary,

Alberta, Canada) elects Bill Cummins
chief financial officer.
ESR Technology Ltd. (Warrington,
U.K.) appoints Roel Berendsen vice
president of the Aviation Division.
Hartmut Wallraf becomes chairman of
The FDT Group (Diegem, Belgium).
Oetinger
Maroske
Golden
Honeywell (Morristown, N.J.) elects

Jae Cho president of the Specialty Materials business.
Jim Oetinger is promoted to director

of technology by Paratherm Corp.
(West Conshohocken, Pa.).
Sudipta Bhattacharya is appointed

president of the Wonderware Business
Unit of Invensys (London, U.K.).
Dirk Maroske is named president of

Schenck AccuRate (Whitewater, Wis.)
Nanmac Corp. (Framingham, Mass.)

elects Anand Pandey director of sales
engineering.
Solutia (St. Louis, Mo.) elects Ray

Kollar vice president of commercial
services for its Flexsys business.
Christopher Golden becomes sales manNovasep Group (Pompey, France)

ager of Industrial Water Treatment for
appoints Urs Geisel sales manager of
Taylor Technologies (Sparks, Md.). n
Ad 385-3c ChemEng:Layout 1 12/10/07 9:59 AM Page 1
Dynamit Nobel GmbH ES.
Kate Torzewski
Particulate Monitors
Emissions Filter Leaks Flow
For over 65 years, Mueller has earned

distinction for delivering outstanding
equipment and unique solutions to the
process industries.
ADVANCED TECHNOLOGY
FilterSense particulate monitors for stacks, baghouses, cartridge

filters and process flow pipes employ a unique combination of
induction-sensing and a protected-probe to perform reliably in
difficult applications. This advanced technology is combined with
user-friendly operation and rugged construction to outperform
traditional triboelectric monitors.
Your production plant is an integrated

system that requires a broad range of
disciplines to optimize.
Paul Mueller Company has the technical
expertise, innovative engineering, and
manufacturing resources to implement
a process system specific to your needs.
PROVEN SOLUTIONS
EPA compliant systems with automatic self

checks, 2-wire loop power, low
cost leak detectors, Ethernet,
pressures to 1000 PSI,
temperatures to 1600F or
intrinsic safety, FilterSense has
field proven solutions.
From modular systems to complete

turnkey plants, when you think of
process, think
TIME & MONEY SAVING BENEFITS
Plan maintenance, prevent product loss,

protect equipment and optimize your process.
FilterSense particulate monitors provide a fast
return on investment.
FilterSense
Analyze, Optimize, Comply
1-978-927-4304
www.filtersense.com
28
2007-08 Paul Mueller Company
385-3c
28 CHE 1-08.indd 28
12/26/07 1:26:18 PM
Master Bond
Spectroline
JANUARY
VICI Metronics
This dye injector fits the needs

of large refrigeration systems
The BigEZ (photo) is the only dye
injector for large refrigeration systems, holding enough fluorescent
dye to treat systems that contain
up to 16 gal of lubricant. This multidose injector has a disposable dye
cartridge that is calibrated in 1/8
oz increments, allowing technicians
to add the desired amount of dye to
a system in one connection without
pouring or measuring. A disposable
cartridge is pre-filled with four ounces
of AR-GLO fluorescent leak detection
dye, which is OEM approved by major
compressor, refrigerant, lubricant,
and air-conditioning and refrigerants
equipment manufacturers. Spectroline, Westbury, N.Y.
Nanosilica improves the physical
properties of this epoxy
This nanosilica-filled, UV-curable
epoxy (photo) was developed for coating, sealing and encapsulation applications. It operates in a temperature
range from 50 to 150C. After curing, the UV22 material enhances its
temperature-resistance profile and
improves its chemical resistance, and
adding heat will give it a glass transition temperature of 275C. Though
UV22 has more than a 35% composition of nanoparticles, it retains high
transparency and low viscosity without sedimentation thanks to the agglomerate-free colloidal dispersion of
nanoparticles. This material features
high abrasion resistance, optical clarity, low shrinkage, and high physical
strength. Master Bond Inc., Hackensack, N.J.
centrifugal pumps. They feature a

steep contact angle of 40 deg. and are
designed for universal mounting, including arrangements of face-to-face,
back-to-back and tandem. The raceways in the inner and outer rings can
accommodate combined radial and
axial loads and provide high-thrust
load capacity, low friction losses and
reduced edge stresses. With a precision level of ISO P6, these SKF bearings allow for better control of their
mounted clearance as well as less
overall vibration. A heat-treating process stabilizes the rings and minimizes
dimensional changes at temperatures
of up to 125C. SKF USA, Inc., Norristown, Pa.
These ball bearings are designed

for universal mounting
SKF single-row, angular-contact ball
bearings (photo) are designed to meet
high performance requirements of
Use this industrial toggle switch

over a range of power levels
The QPL-certified 12000X778 toggle
switches (photo) feature a doubleshell case that provides mechanical
SKF USA
APEM
Components

strength and electrical insulation. A

pinned lever adds strength and ensures a strong electrical ground to the
bushing. These switches can be used
in both low-level (10 mA, 50 mV) and
power-level (2 A, 250 Va.c. 4 A, 125
Va.c.) applications. An electrical life
of 20,000 to 150,000 cycles is typical.
For low-visibility situations, a white
fluorescent tip is available. APEM
Components, Inc., Haverhill, Mass.
Release pure compounds into
solution at a steady rate
Dynacal Permeation Tubes (photo)
are small inert capsules that contain
a pure chemical compound in equilibrium between its gas and liquid or
solid phases. Concentrations range
from levels of parts-per-billion to
high parts-per-million. At a constant
temperature, the tubes emit the compound at a constant rate through its
permeable membrane. The purpose
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:28D-1
New Products
Bessamaire
of a calibration gas is to establish a

reference point for the verification of
an analysis. If permeation-rate data is
not available for a certain compound,
the Permeation-Tube rate can be
found simply by measuring the gravimetric weight loss of the capsule of a
measured period of time at a known
temperature. VICI Metronics, Inc.,
Poulsbo, Wash.
Measure temperatures up to
800C from a distance
Featuring broad infrared temperature
measurement functionality, the Fluke
568 Thermometer (photo) offers both
contact and non-contact temperature
measurement. It offers a broad temperature range of 40 to 800C with
measurement accuracy within 1%.
This handheld device has a user interface that allows for adjustable emissivity, alarms and data logging. Allowing users to take measurements of
small objects from far away, the Fluke
568 features a distance-to-spot ratio
of 50:1. Measurements can be viewed
in realtime to troubleshoot via handsfree monitoring. For easy analysis,
this unit can store up to 99 points of
data to view on the thermometer itself
or on a PC after downloading. Fluke
Corp., Everett, Wash.
These rugged sensors can be
used at low depths
The PT-500 submersible liquid level/
pressure transmitters feature a
vented, watertight cable and can be
submerged up to 450 ft below the surface. The unit has a removable stainless steel cage that allows users to
replace either the cage or sensor individually. Using a high-precision, 420mA signal, the PT-500 transmitters
deliver accuracy within 0.5%. They
are IP68 protected and are temperature compensated to ensure long-term
stability under extreme temperature
variations. The unit is designed to
mount to a surface, eliminating damage from shock and vibration, making
it ideal for use in sewage lift stations,
tank liquid-level measurement, water
and wastewater, well depth measurement and environmental water depth
measurement. Automation Products
Fluke Corp.
Group, Inc., Logan, Utah

Take full advantage of
Mathematica with new add-ons
This firm offers an updated suite of
add-ons for Mathematica 6, extending
its functionality to specialized tasks.
These packages allow users to take
full advantage of Mathematicas power
without having to develop code of their
own. Several applications are compatible with Mathematica, including
multi-language, multi-environment
numerical code generation (ACEGen),
optimized C++ code conversion from
Mathematica programs (MathCode
C++), a model-based design for multiengineering systems (MathModelica
System Designer Professional), a
Mathematica link for Excel, and more.
Wolfram Research, Champaign, Ill.
This cooler provides sufficient
power in a low-profile unit
The KUBE low profile evaporative
coolers (photo), a series of industrial/
commercial cooling and heating products, are just 48-in. in height. The
FreshWater slinger-wheel technology distributes evaporative atomized
water evenly across the air inlets for
efficient cooling. KUBE coolers work
from 3,000 to 30,000 ft3/min. with variable speed control. Heating is provided
through an indirect heat exchanger at
up to 400,000 Btu per unit. The units
are network capable, and touch-screen
controls allow up to 15 units to be controlled remotely. The units use a fourstage filtering process, including a
28D-2$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
final food-grade filter. Highly energyefficient, the KUBE products consume

up to 90% less electricity than conventional air conditioning. Bessamaire,
Cleveland, Ohio
This control monitor offers
realtime reports
The Westlock XR linear-rotary control
monitor is the first stand-alone field
device to create a dynamic baseline
signature for pressure conditions of
valve assemblies, according to this
firm. It is designed to provide process
managers with critical information
quickly and in a wide range of formats, and is used in conjunction with
the associated software package, the
XRa. Features of the XR include an intelligent alarm-management system,
a non-contact position sensor, a fullyencapsulated electronics module and
integrated pressure sensors. Tyco
International, Cleveland, Ohio
Fluid modeling is easier with
improved software capabilities
This company has recently released
Version 8.1 of its Engineering Fluid
Dynamics (EFD) software. The Joule
heating functionality is a model that
automatically determines the heat
sources in conducting objects. To represent thermal characteristics of IC
packages, the compact models use a
two-resistor approach to provide realistic results. Other models and capabilities include fans, thermoelectric
coolers, thermal interface materials,
perforated plates and material prop-
Space at a premium?
Compact Fisher-Klosterman MS Series Particulate Scrubbers save
valuable plant space, allowing for additional processing equipment. Our innovative
design provides efficient particle and water droplet removal at gas velocities much higher
than larger, more expensive, traditional cyclonic separators, without the use of internal
baffles or packings. Its a system thats so efficient, we offer guaranteed performance
when provided with complete operating information.
Fisher-Klosterman will have your plant swimming in profits.
Dust Collection Product Recovery Pollution Control
(502) 572-4000
Fax: (502) 572-4025
fki@fkinc.com
fkinc.com
Come see us Oct. 30 Nov. 1, 2007

in New York City. Booth #500.
28D-3 CHE 1-08.indd 3
12/13/07 3:19:36 PM
New Products
DSM Somos
erties for most solid materials used in

electronic systems. EFD has the ability to detect fluid regions within a CAD
solid model and mesh automatically,
but with the updated Version 8.1, this
improved capability also detects and
closes any external gaps or openings
in the solid model automatically. Flomerics, Marlborough, Mass.
For ultra clarity,
choose this resin
This company offers the WaterClear
Ultra, a colorless stereolithography
(SL) resin that is claimed to be the
clearest resin on the market. The
clearness test (photo) was performed
using a colorimeter, an instrument
that measures the amount of color
and light able to pass through plastic.
Compared to various plastic samples,
including a competitive polycarbonate-like ASL resin as well as polycarbonate and acrylic, the WaterClear
Palmer Wahl
Instrumentation
Group
Ultra closely mirrored the behavior

of the acrylic while proving to have a
higher clarity than the commercialgrade polycarbonate sheet. Products
that demand very clear material, like
prototype lenses and packaging materials, would benefit from the WaterClear Ultra. DSM Somos, Elgin, Ill.
This thermal imager measures
19,200 pixels in realtime
The long distance model HSI3003
PROTECT PUMPS
Cavitation
Bearing Failure
Dry Running
Overload
TRUE POWER LOAD DISPLAY

Best Sensitivity
4-20 MILLIAMP
ANALOG OUTPUT
TWO ADJUSTABLE SET POINTS
Relay Outputs
Adjustable Delay Timers
UNIQUE RANGE FINDER SENSOR
(photo) is the newest addition to the

Heat Spy thermal imaging cameras.
Its narrow angle 9.1 deg. by 6.8 deg.
field-of-view optics enables detection
and temperature measurement of
small objects over a long distance. Intended for hand-held use, the HSI3003
is lightweight and compact, but also
features a tripod mount for remote use.
COMPACT EASY MOUNTING
Works on Wide-range of Motors
Starter Door
Panel
Simplifies Installation
Raceway
Wall
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TRONOX INC. LLC

Late Model
Inorganic Oxide Powder Manufacturing

& Powder Processing Equipment
Most Assets New, Never Installed &
Designed for State-of-the-Art
High Speed Production
Bid Submission Deadline:
February 28, 2008 3pm MT
Preview: By Appointment Only
Preview Location: Soda Springs, ID
Kiln: Harrop 100', With Heated Mesh
Spray Dryer Atomizer: 10' (Never Installed)
Reactors: 2000-Gallon Stainless Steel;
1500-Gallon Glass-Lined
Vacuum Pumps; Pumps; Rotary Airlock Valves;
Air Compressors; Blower Fans; Substations;
Transformer; Trailers
For further information or preview appointment,
please contact Doug Escudero
Phone: 650.207.9927 E-mail: descudero@dovebid.com
www.dovebid.com
WWW.LOADCONTROLS.COM
28D-4$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
A Buyers Premium is in Effect

CA Bond #69567717
The imager features a 160- by 120pixel array, providing temperature

measurements of every pixel in
a high-resolution realtime thermal image on a 3.5-in. color display. Sensing temperatures from
0 to 250C, it has a Class II laser
that identifies hot areas. Another
useful feature is a system of two
measurement cursors that provide
temperature readings at each cursor location as well as realtime
differential temperature measurements. Palmer Wahl Instrumentation Group, Asheville, N.C.
Take advantage of continuous
processing with this reactor
First introduced as a prototype at
Achema 2006 (CE, June 2006, p. 13)
the ART Plate Reactor (photo) is now
commercially available. The reactor
allows manufacturers to switch from
batch to continuous processing, and
is particularly suitable for the fine
chemicals, pharmaceuticals and biotechnology industries. ART is a continuous reactor with major benefits
in economy, production safety and
environmental impact. Compared to
stirred-tank reactors (STRs), ART
reactors allow faster scale up and
improved yield, and provides better
control of reactions. For example, reactions that require 6 to 8 h in a STR
for 8090% yield are performed in less
than minute in the ART reactor with
better than 99% conversion, says the
firm. The reactor can operate over the
temperature range of 40 to 200C,
handles pressures up to 20 bar, and
is available in two sizes for flowrates
of 0.25 to 250 L/h. One to ten plates
can be stacked into a single unit. The
plates are available in a variety of materials, including 316L stainless steel,
PEEK and Hastelloy C22. Alfa
Laval AB, Lund, Sweden
Up to 32 field devices
are handled by this transmitter
The TFZ Foundation-Fieldbus (FF)
Temperature Transmitter (photo)
can be installed on the same segment with all standard FF devices.
The TFZ converts a temperature
sensor input to a FF H1, two-way
Alfa Laval
digital
communication protocol
that is ready for
interface to a DCS,
c o m p u t e r- b a s e d
SCADA
system
or asset-management
software.
The TFZ saves
wire and installation costs, says
the firm, by allowing up to 32 field
Moore IndustriesInternational
devices (126 with
repeaters) to be networked onto one,
low-cost FF H1 segment. It requires
only 10.5 mA for normal operation.
The bus-powered, two-wire device
sets up from the control room over
segment wiring using a standard
FF configuration tool, to handle 14
RTD types, nine thermocouple types
as well as direct millivolt and resistance/potentiometric inputs.
Moore Industries-International, Inc.,
North Hills, Calif.
This material has the benefits of
liquid silicone and fluorosilicone
Composed of 100% Fluoro Liquid
Silicone Rubber (F-LSR), the Silastic
elastomer is designed to meet stringent automotive engine requirements
regarding temperature, fuel and oil
specifications. F-LSR combines the
ease of processing of liquid silicone
rubber with the temperature and fuel
resistance of fluorosilicone rubber. Silastic withstands harsh fuel, lubricant
and oil environments with tempera-
New Products
ture resistance within the range of 60
to 220C. This material, well suited for
co-molding on thin, high precision and
intricate parts, improves manufacturing efficiency and part performance.
Dow Corning, Midland, Mich.
Sunlight does not impede the accuracy of this transmitter
The new version of the Mobrey
MSP900 ultrasonic level transmitter
has been optimized for use in openchannel flow measurements. The
MSP900FH (photo), which features a
pre-wired remote temperature sensor,
is ideal for helping water and industrial processing sites to comply with
MCERTS legislation. Used in the
open air, conventional U.S. level transmitters are prone to suffer from inaccuracies caused by solar gain whenthe sun shines directly on them. The
MSP900FH has been designed to overcome this problem by using a remote
Premo
temperature sensor wired

directly into the transmitter.
The sensor is hardwired into
the transmitter with a twometer cable, so there is no
additional cabling or setup
required, and only a single connection to the controller. Both analog
420 mA communication and digital
HART options are built in. Emerson
Process Management, St. Louis, Mo.
The latest in
RFIS antennas
This company claims to be the first
in the world to integrate three single
RFID antennas in one, monolithic
component several years ago. Since
the device was patented in 2001, the
firm has introduced a new RFID antenna (photo) that is said to offer the
28D-
Emerson
maximum sensitivity in the smallest

space. It is recommended for RKES
and RFID access systems that integrate 3D identification. The antenna
is suitable for SMD mounting, offering
a flat surface for pick and place. Antennas are available for 20 and 125kHz applications. Premo Corp. S.L.,
Campanillas, Malaga, Spain
Track equipment health
without wires
In collaboration with SKF, this firm has
introduced OneWireless Equipment
Health Monitoring (EHM), the latest
28D1-7 CHE 1-08.indd 6
12/26/07 4:01:46 PM
addition to its portfolio of industrial

wireless solutions. OneWireless EHM
will wirelessly transmit complete spectral information including vibration
amplitude and operating-parameter
information from the field to the
plant control room, helping reduce
equipment failures and improve business performance through lower maintenance costs, says the firm. OneWireless is a compact, eight-channel (4 X
vibration, 4 X 420 mA) monitoring device that communicates over the firms
OneWireless industrial mesh network.
It collects acceleration, velocity, temperature and bearing-condition data
and delivers it to process operators and
maintenance personnel to alert them of
any equipment problems. Honeywell
Process Solutions, Phoenix, Ariz.
An RFID system alerts against
pallet tampering
Together with Pliant Corp. (Schaumburg, Ill), this firm has successfully
demonstrated a solution for tamperproofing pallets with RFID-enabled
stretch film (shrink wrap). Pliants
electrically conductive stretch film
combined with this firms PowerG
labels for tracking freight and highvalue pallets provides a viable solution by overcoming the limitations of
barcode technologies, the limited performance of standard passive RFID,
and the high cost of active RFID readers, claims the manufacturer. Electrically connected to the film wrapped
around the pallet, the PowerG label
is readable by RFID readers when the
film is intact and the electrical circuit
is closed. However, when the stretch
film is tampered with, the circuit is
broken, rendering the label unreadable and thereby alerting a supplychain manager to possible tampering.
PowerID Ltd., Petah Tikva, Israel
The pumps feature power-supply and

control modules that can be mounted
in various configurations directly on
the pump, or remotely, thereby eliminating cables and accessory racks.
The first pump in the iXA family is
rated at 2,200 L/s larger sizes are
planned for future development. The
pumps five-axis magnetic-bearing
system and new motor and drive system ensure long life and low operating cost with maintenance intervals
as long as five years, says the firm.
All pumps include RS 232/485 (Profibus) serial-communication interfaces.
Edwards, Wilmington, Mass.
Kate Torzewski
Drrs Proven VOC Control Systems
Engineered Abatement Systems for Environmental Compliance
Your Needs, Our System.

Drr provides complete technology and
solutions to keep your plant in continuous
compliance. With the dynamic combination of our Single Rotary Valve RL RTO and
our 30+ years of experience in almost
every sector of industryDrr has the
answer for your VOC abatement needs.
Durr offers complete After Market
Services such as Spare Parts, Retrofits,
Performance Contracts, and Scheduled
Maintenance for VOC equipment of any
make. These services will keep your
system continuously running and technologically up to date.
This turbopump is suitable for

processing electronics chemicals
The new iXA Series of magnetic-bearing turbomolecular vacuum pumps
exhaust process gases from physical
and vapor deposition, etching, or ionimplant equipment in semiconductor,
flat-panel display, solar energy and
industrial-glass-coating applications.
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Phone: +1 734-254-2314
E-mail: EESsales@durrusa.com
Circle 31 1on p. 58 or go to adlinks.che.com/7368-31
6/12/2007 11:05:37 AM
28D1-7 CHE 1-08.indd 7
28D-
12/26/07 4:02:08 PM
Global Interaction Technology Solutions

Lowering Risk Total Execution
Achieving Max
Performance with
Limited Resources.
Who Should Attend:
CEOs CTOs CIOs
Why Should You Attend:

Participate in strategic
discussions
Network with and learn from
your peers from around the world
Discover innovative ideas and
best practices
See emerging technologies
Create strategic alliances
JANUARY 28-30, 2008

WYNDHAM GREENSPOINT HOTEL
HOUSTON, TEXAS
FOR MORE DETAILS VISIT WWW.DARATECHPLANT.COM OR CONTACT KIM ARELLANO AT

832.242.1969 EXT. 313 OR KIMA@TRADEFAIRGROUP.COM
Organized by:
Media Partners:
12775
28D-8 CHE 1-08.indd 8
12/20/07 6:49:37 PM
ProMinent
JANUARY
Take full advantage of continuous

processing with this new reactor
First introduced as a prototype at
Achema 2006 (CE, June 2006, p. 13)
the ART Plate Reactor (photo) is now
commercially available. The reactor
allows manufacturers to switch from
batch to continuous processing, and
is particularly suitable for the fine
chemicals, pharmaceuticals and biotechnology industries. ART is a continuous reactor with major benefits
in economy, production safety and
Malvern
environmental impact. Compared to
Instruments
stirred-tank reactors (STRs),
ART reactors allow faster scale
up and improved yield, and provides better control of reactions.
For example, reactions that require 6 to 8 h in a STR for 80
90% yield are performed in less
than minute in the ART reactor
with better than 99% conversion,
says the firm. The reactor can
operate over the temperature
range of 40 to 200C, handles
pressures up to 20 bar, and is
available in two sizes for flowrates of 0.25 to 250 L/h. One to Siemens Automation and Drives
ten plates can be stacked into a
single unit. The plates are available in maximum safety integrity levels up to
a variety of materials, including 316L SIL 3, for example, for burners. Siestainless steel, PEEK and Hastelloy mens Automation and Drives, NuremC22. Alfa Laval AB, Lund, Sweden
berg, Germany
for facilities with multiple lines and

for commissioning, optimization and
troubleshooting applications. Malvern Instruments, Malvern, U.K.
A new controller for when safety

is especially important
The Simatic CPU S7-412-3H (photo) is
a new controller for high availability,
safe and fault-tolerant applications
in the process industries. It complements the range of products of the
Simatic-S7-400H family of controllers
in the low-performance range. The
new device is suitable for applications
involving high-availability functions
for monitoring and closed-loop control of temperatures, liquid levels and
emergency power generators, as well
as safe, fault-tolerant solutions with
Don't let gas disrupt

your dosing operation
Gas-emitting media in metering applications can often reduce pump
output or even prevent the pumped
media from being delivered. To
avoid this situation, the pumps normally have to be bled manually in
such applications. This procedure
can be performed simply and safely
with the delta Diaphragm Metering
pump with venting module (photo).
The module detects the formation of
gas bubbles in the pump head and
eliminates them, preventing adverse
Take this particle analyzer where

and when its needed
With a refined user-friendly design,
the new Insite Voyager (photo) is particularly adapted for mobile particlesize analysis within the process environment. Smaller and lighter than
the original version, the unit can now
be operated at- or online, thereby providing realtime analysis where and
when required. The laser-diffractionbased analyzer can be used on dry
streams with a particle-size range of
1 to 1,000 microns. The mobility of the
system makes it particularly suitable

Alfa Laval
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:28I-1
Moore Industries-International
New Products
performance or service
disruption in metering
lines. The venting function is executed periodically
or after airlock detection.
ProMinentDosiertechnik GmbH,
Heidelberg, Germany
The latest in
RFIS antennas
This company claims to be the first
in the world to integrate three single
RFID antennas in one, monolithic
component several years ago. Since
the device was patented in 2001, the
firm has introduced a new RFID antenna (photo) that is said to offer the
maximum sensitivity in the smallest
space. It is recommended for RKES
and RFID access systems that integrate 3D identification. The antenna
is suitable for SMD mounting, offering
a flat surface for pick and place. Antennas are available for 20- and 125kHz applications. Premo Corp. S.L.,
Campanillas, Malaga, Spain
Valves for
LNG transportation
Liquefied natural gas (LNG) has only
one to six hundredth of the volume
of gaseous natural gas, thus is more
suited for economical transportation of large quantities; for distances
over 3,000 km, vessel transportation
of LNG is said to be more profitable
than via pipeline. Cryogenic valves
designed for use down to 196C, and
this firms bypass valves for two parallel nitrogen compressors have recently
been delivered for use on LNG vessels.
The N2 compressor is an expander
that is switched afterwards for cooling
the plant. To regulate the temperature
of this expander, the firm delivered the
temperature-control valves designed
for 196C. ARCA-Regler GmbH,
Tnisvorst, Germany
Up to 32 field devices
are handled by this transmitter
The TFZ Foundation-Fieldbus (FF)
Temperature Transmitter (photo) can
be installed on the same segment with
all standard FF devices. The TFZ converts a temperature sensor input to a
Premo
FF H1, two-way digital communication protocol that is ready for interface

to a DCS, computer-based SCADA system or asset-management software.
The TFZ saves wire and installation
costs, says the firm, by allowing up to
32 field devices (126 with repeaters) to
be networked onto one, low-cost FF H1
segment. It requires only 10.5 mA for
normal operation. The bus-powered,
two-wire device sets up from the control room over segment wiring using
a standard FF configuration tool, to
handle 14 RTD types, nine thermocouple types as well as direct millivolt
and resistance/potentiometric inputs.
Moore Industries-International,
Inc., North Hills, Calif.
Sunlight does not impede
the accuracy of this transmitter
The new version of the Mobrey
MSP900 ultrasonic level transmitter has been optimized for use in
open-channel flow measurements.
The MSP900FH, which features a
pre-wired remote temperature sensor, is ideal for helping water and
industrial processing sites to comply
with MCERTS legislation. Used in
the open air, conventional U.S. level
transmitters are prone to suffer from
inaccuracies caused by solar gain
when the sun shines directly on them.
The MSP900FH has been designed
to overcome this problem by using a
remote temperature sensor wired directly into the transmitter. The sensor is hardwired into the transmitter
with a two-meter cable, so there is no
additional cabling or setup required,
and only a single connection to the
controller. Both analog 420 mA communication and digital HART options
are built in. Emerson Process Management, Slough, U.K.
This turbopump is suitable for
processing electronics chemicals
The new iXA Series of magnetic-
28I-2$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Edwards
bearing
turbomolecular
vacuum
pumps (photo) exhaust process gases
from physical and vapor deposition,
etching, or ion-implant equipment
in semiconductor, flat-panel display,
solar energy and industrial-glasscoating applications. The pumps feature power-supply and control modules that can be mounted in various
configurations directly on the pump,
or remotely, thereby eliminating
cables and accessory racks. The first
pump in the iXA family is rated at
2,200 L/s larger sizes are planned
for future development. The pumps
five-axis magnetic-bearing system
and new motor and drive system ensure long life and low operating cost
with maintenance intervals as long
as five years, says the firm. All pumps
include RS 232/485 (Profibus) serialcommunication interfaces. Edwards, Wilmington, Mass.
A new member added to this family of materials-testing machines
This firm has enhanced its range of
zwicki-Line universal testing machines. They are now available in four
load capacities (0.5-, 1.0-, 2.5- and a
new 5-kN model), and three different height combinations to suit most
applications and laboratory requirements for testing materials and components. These new products are fitted with the manufacturers latest
testControl system, and are designed
to meet the needs of both R&D laboratories and quality-assurance environments. Test and crosshead-positioning
speeds of up to 3,000 mm/min enable
high-speed tests or short cycle times,
which is useful for the testing of elastomers and springs. Zwick GmbH &
Co. KG, Ulm, Germany
In perfect harmony.
Excellent performance!
Berndorf Band has always worked closely
together with its customers and strives
to meet or exceed the customers steel
belt requirements. Berndorf Band can find
the right solution for any application.
Due to careful selection of high quality

raw materials and new state of the art
production facilities, our goal is to ensure
the customers will receive best results
with process steel belts made by Berndorf
Band.
BERNDORF BAND GMBH

A-2560 Berndorf, Austria
Phone: (+43)2672-800-0
Fax:
(+43)2672-84176
band@berndorf.co.at
www.berndorf-band.at
Berndorf Bienen 206x279.indd 1
28i-3 CHE 1-08.indd 3
20.12.2007 10:13:33 Uhr
12/21/07 9:27:13 AM
New Products
This machine can wash,
dry and rinse
The T 406 machine (photo) can be used
at several places in the processing line
of plants that recycle mixed plastics
waste. It can serve as a friction washer
after the size-reduction step to unravel
paper ands separate dirty water from
the product stream. It can also be used
as a mechanical drying centrifuge at
the end of the washing process; with
hot washing systems for separating
glues, the T 406 can do the job of an
alkali separator. The unit can be supplied with drives up to 30 kW, and
will achieve a throughput of up to 2
m.t./h. Herbold Meckesheim GmbH,
Meckesheim, Germany
Herbold Meckesheim
WIKA
Samson
IPI Global
If you process hydrocarbons,

consider these control valves
This firm has developed a range of control valves (photo)
that can be tailored to the individual requirements of an application, and therefore meet the challenges faced in most
Fixed Date Private Treaty Sale
TRONOX INC. LLC
Pressure transmitters
made in Germany
This firm has developed an intelligent production line
for making its A-10 pressure transmitters (photo). Hardly
any solder joints are needed, and faults are avoided from
the beginning by automatic monitoring of each production
step. Only five components and nine production steps are
required to manufacture this new transmitter. Extensive
field tests have proven the A-10s capabilities under real
operating conditions, says the firm. WIKA Alexander
Wiegand GmbH & Co. KG, Klingenberg, Germany
Late Model
Inorganic Oxide Powder Manufacturing

& Powder Processing Equipment
Most Assets New, Never Installed &
Designed for State-of-the-Art
High Speed Production
Bid Submission Deadline:
February 28, 2008 3pm MT
Preview: By Appointment Only
Preview Location: Soda Springs, ID
Kiln: Harrop 100', With Heated Mesh
Spray Dryer Atomizer: 10' (Never Installed)
Reactors: 2000-Gallon Stainless Steel;
1500-Gallon Glass-Lined
Vacuum Pumps; Pumps; Rotary Airlock Valves;
Air Compressors; Blower Fans; Substations;
Transformer; Trailers
For further information or preview appointment,
please contact Doug Escudero
Phone: 650.207.9927 E-mail: descudero@dovebid.com
www.dovebid.com
A Buyers Premium is in Effect

CA Bond #69567717
28I- Chemical Engineering www.che.com January 2008
28i1-4 CHE 1-08.indd 4
hydrocarbon-processing applications. The valves are available in globe, angle and three-way body styles, in all common
pressure ratings and in all common materials of construction. The 240 and 250 Series are designed to conform with
ANSI, DIN and JIS standards and can be combined with
various flange styles and butt-weld ends. Pneumatic actuators with a rolling diaphragm and springs evenly arranged
in the actuator case are made to precisely fit on valves over
robust yokes to ensure a compact and integral control-valve
package. Samson AG, Frankfurt, Germany
Use this couple for safe transfer

of hazardous materials
The Advanced Dispense System (ADS) Coupler (photo) connects to the plastic CDS valve on AdBlue and IBCs and
allows the quick transfer of the contents in a leak-proof
and closed system. The ADS is made of stainless steel
1.4301 (AISI 304), has a 1-in. BSP male connection, has a
self-venting capability and provides a minimum flowrate
of 30 L/min. The unit has a dry disconnect volume of less
than 0.5 mL and is fully compatible with plastic valve connection (CDS). Designed for use with the AdBlue dispense
kit, the ADS can also be used for other types of chemicals
in drums and IBCs equipped with the CDS plastic valve.
IPI Global Ltd., Chinnor, U.K.
Gerald Ondrey
12/26/07 3:50:25 PM
italia 2008 chem.qxd
17-12-2007
15:36
Pagina 1
italian jewels
28i5-16 CHE 1-08.indd 5
12/26/07 3:38:35 PM
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28I-6]]]]]]$)&.*$"-&/(*/&&3*/(]]]]888$)&$0.]]]]+"/6"3:
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NEW
ROBOX evolution ES 5:
Compact Blower package for

the WWT industry
Complete range: from 240 up to 10.500 m3h.
Robuschi RBS 3 lobe P. D. Blower with a
patented device to reduce the pulsations:
LOW PULSE.
Low noise: < 5 d(B)A under all types of
operating conditions.
ROBOX evolution ES 5 can be transported
easily fully assembled without removing
enclosure.
LOW MAINTENANCE
LOW PULSE
LOW NOISE
Sentinel: Electronic
monitoring system
Simple oil change
Easy oil check
PUMPS AND BLOWERS

ROBUSCHI S.p.A. Via S. Leonardo, 71/a 43100 PARMA - ITALY
Italia Tel. +39 0521 274911 Export Tel. +39 0521 274991 Fax +39 0521 771242
e-mail: robuschi@robuschi.it
www.robuschi.com
28i-7 CHE 1-08.indd 7
12/13/07 3:27:27 PM
Italy Special Advertising Section
Elisabetta | Dreamstime.com
Continued from p. 28I-6
Pump innovation
Consistent investment gives
Finder Pompe the edge
Multinationals are important to Italys chemical industry, but

smaller firms and SMEs play essential roles as well
side, Italian chemical companies, especially in the fine and specialty sector, are set to benefit from this repositioning, as they
represent valuable partners in the development of new products.
The Italian automotive industry, another significant customer
for the chemical industry, will also see a significant slowdown in
2008. This follows a dynamic performance in 2007, thanks to the
launch of new models and incentives to buy less-polluting cars.
Looking for exports

Italian chemical companies are very conscious of the importance
of capturing foreign demand: between 1992 and 2006 their propensity to export grew by 19 percentage points. Thanks to this
impressive growth, the chemical industry today is Italys leader
in terms of its share of exporting companies (45%). The trend
involves not only big companies but also SMEs.
In 2006 Italys share of world chemicals trade was about 2.8%.
Higher market shares emerge in two specific sub-sectors: detergents and cosmetics (6.3%) and paints, varnishes and adhesives
(6.1%). If we consider that Italian manufacturing as a whole represents 3.5% of world trade, it is clear that these sub-sectors are
very successful not only in terms of the chemical industry but for
Italian manufacturing as a whole.
In 2007 these sub-sectors further improved their export performance: Italys trade balance in detergents and cosmetics was
1,245 million, while for varnishes, adhesives and inks it was
650 million. The export performance of the varnishes, adhesives
and inks sector was particularly positive, with export growth
estimated at 13% (in value terms). This is the result of very good
performance in well-established markets such as Germany and
Spain, and also of rapid growth in emerging markets like Poland,
Russia, Asia and the Middle East. In 2008, however, the strong
Euro, and slowing demand both within and outside Europe, mean
that chemical exports are unlikely to grow dynamically. Italys
trade deficit is therefore expected to worsen.
The profitability of Italian chemical companies, especially in
the specialty sector, has been under pressure for several years.
This trend will not change in the short term, since oil and energy
costs are expected to remain very high. 2007 also saw rises in the
prices of basic inorganics and other raw materials such as oil and
fats. Enterprises have reacted by increasing efficiency, rationalizing their product portfolios, focusing on innovation, and addressing themselves to the most dynamic markets.
www.federchimica.it
he year 2007 was marked by record sales

and other significant successes in the oil
and gas market segment, says pump manufacturer FInder Pompe.
In the companys range of API 610 process pumps, the HPVT line proved extremely
successful. HPVT pumps are vertically-suspended, multistage designs with bowl-type
diffuser casings, axial suction and discharge, and closed impellers with individual
thrust balancing and wearing rings back and
front. HPVT-DS types have a double-suction first stage impeller to ensure low NPSH
requirements.
HPVT pumps can be supplied in either
VS1 or VS6 configuration as specified by
API 610. VS6 pumps are normally used
in low-boiling-point services such as
liquefied gas or condensate extraction.
Depending on pump length, the drive
column can be fitted with one or more
intermediate lineshaft bearings.
The shaft is generally made in one
piece for optimum straightness and reliability. Jointed-shaft versions are used for
pump lengths exceeding 6m.
Line bearing lubrication is normally provided by the fluid being pumped. The rotor
axial thrust is supported by thrust bearings
located in the discharge head; bearings can
be either grease or oil lubricated.
API 682 single or dual mechanical seals
are normally used. A rigid intermediate
coupling with spacer allows the mechanical
seal cartridge to be removed without disconnecting the motor or the discharge head.
The pump is also fitted with an adjustment
system for axial rotor positioning.
API 610 vertical pumps from Finder Pompe also
include the HPVVS4 line of vertical sump pumps.
Each HPV pump is engineered to customers specifications,
including a choice of pump length in the range 0.56.5 m below
the mounting plate. Standard construction features include a single-piece shaft guided by sleeve-type line bearings in materials to
suit the application. The mounting plate, which is an integral part
of the pump, can be designed as either square or round, to match
sump or tank plates or flanges. A mounting flange with the same
pressure rating as the corresponding part of the tank is available
as an option.
Both HPV and HPVT pumps can be manufactured in several
material combinations, including duplex stainless steel and other
corrosion-resistant alloys. They are used for a wide range of applications in the oil and gas, petrochemical and chemical industries.
As well as the HPV and HPVT ranges, Finder Pompe products
for the process industries include the well-known HPP series and
the successful PEP and DualPEP ranges of low-flow, high-head
pumps. All are available to API 610 10th ed. or API 685 1st ed.
www.finderpompe.com
28I-||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||JANUARY 2008
28i5-16 CHE 1-08.indd 8
12/26/07 3:40:08 PM
Italy Special Section
Simply
a better
blower
Robuschi has a new, higher-capacity
version of its ROBOX packaged blower
obuschi has established

a leading position in
European markets, and an
international reputation as
an expert in blower and pump
systems specializing in custom solutions. The company
responds quickly to customers
changing needs, anticipating
and developing systems to
combine performance with the
lowest possible costs.
With its ROBOX evolution
compressor package, Robuschi
has set new standards in positive displacement rotary blowers. Continuing the success of
the ROBOX evolution series
1-2-3-4, the new series 5 provides differential pressures up
to 1,000mbar at capacities of
8,00010,500m3/h.
When it comes to noise,
the new series 5 provides cutting-edge performance, with
sound levels 5dB(A) below
those of the previous series
under all operating conditions. Contributing to this is
an updated discharge silencer
that is even stronger and more
reliable. It consists of a series
of diffusion chambers and resonators, with no soundproofing material on the inside.
The acoustic enclosure has
also been improved, through
better channelling of the
exhaust and ventilation air, and
double soundproofing panels
on some parts of the enclosure.
Special consideration has
been given to making maintenance even easier. For example, the oil is changed from
outside the acoustic enclosure
by means of two tanks, with
an easy-access drain valve for
the waste oil. The oil level can
be checked from outside the
enclosure and with the blower
running, by means of indica-
tors on the oil filler tanks. The

acoustic filter can be adjusted
and replaced easily by simply
removing the front panel of the
enclosure.
Automatic belt tensioning
via an oscillating suspension
system for the motor maintains
the correct belt tension at all
times, and so reduces the load
on the bearings. The automatic
tensioning system also makes
belt replacement easy. This job
is carried out from the front of
the machine without the use of
any additional equipment.
The new ROBOX evolution
is also easy to transport with
the acoustic enclosure already
assembled. As a result, freight
costs are on average only half
those of previous models.
This new model from
Robuschi creates additional
benefits and convenience
when choosing a positive displacement blower package. It
has lower system costs, thanks
to better use of space; lower
operating costs, through its
low energy consumption and
the elimination of all risks of
breakdown, made possible by
the innovative SENTINEL electronic monitoring system; and
low maintenance costs, with
easy accessibility of every part
for routine servicing.
The ROBOX system combines high conveying rates with
the highest reliability in practical applications. Its main applications are modern sewage
plants, where sludge has to be
saturated with large amounts
of fresh air, and the pneumatic
conveying of food, cement,
granulates or other products.
ROBOX evolution is also
available in an ATEX version for
hazardous atmospheres.
www.robuschi.com
28I-10||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||JANUARY 2008
28i5-16 CHE 1-08.indd 10
12/26/07 3:40:38 PM
28i-11 CHE 1-08.indd 11
12/20/07 6:31:48 PM
High-performance solutions for vessel inerting

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28i-13 CHE 1-08.indd 13
1/2/08 11:24:21 AM
Italy Special Advertising Section
Surfactants, detergents and now much more

Desmet Ballestra, a world leader in the design and supply of plants for the production
of surfactants and detergents, is branching out into sulfuric acid, LAB and fertilizers
esmet Ballestra SpA, founded in 1960,

is the world leader in the design and
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Desmet Ballestras film sulfonation
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Beside its core business in detergents
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Compact and flexible packaged vacuum systems

Pompetravaini, well known for liquid-ring vacuum pumps as well as centrifugal
pumps, also supplies packaged vacuum systems for a wide range of applications
ompetravaini is well
known for its liquid-ring vacuum pumps
and centrifugal pumps but not just for
pumps alone. Many plants worldwide rely
on Travaini packaged vacuum systems for
plug and play performance. The smallest of these packaged vacuum systems
are sold under the name of Hydropack.

They are extremely compact vacuum units
capable of total or partial
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Hydropack units are
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Another advantage is the fact that the discharged gas is not contaminated with oil or
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Hydropacks provide high efficiency at

both high and low vacuum, thus saving
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from the process gas. Compact design
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Four standard systems in the
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Hydropacks are suitable for nearly every
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Pompetravaini is a reliable supplier that
has been in business for almost 80 years.
The company has three factories, seven
subsidiaries, and a network of distributors
to provide technical advice, sales, and
service in more than 80 countries around
the world.
www.pompetravaini.com
28I-14||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||JANUARY 2008
28i5-16 CHE 1-08.indd 14
12/26/07 3:43:16 PM
206x279-DSC-04.mep
3/12/07
11:22
Page 1
Desmet Ballestra
Leading technologies
for
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SURFACTANTS
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DETERGENTS
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Spray Drying Tower Process
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Call us at +39 02 50 831

or write to mail@ballestra.com
www.desmetballestra.com
28i-15 CHE 1-08.indd 15
12/20/07 6:34:32 PM
Vegetable oil refining systems

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MENLO PARK
29 CHE 1-08.indd 29
HOUSTON
BEIJING
TOKYO
ZURICH
12/13/07 3:30:36 PM
Feature
Cover
Story
Report
Controlling SO2 Without

Corroding the Bottom Line
Bill Looney and Brian Baleno
Solvay Advanced Polymers, LLC
Greg L. Boles
Koch-Otto York Separations Technologies
Jacob Tetlow
Arizona Public Service Co., Cholla Plant
mong the many types of pollution-abatement systems that

are in use today, wet fluegas
desulfurization (FGD) systems
also known as wet scrubbers are
notoriously capital- and maintenanceintensive. These systems are widely
used by electric power plants and
chemical process facilities to capture
and neutralize sulfur-laden fluegas,
and help plant operators to meet strict
federal and state mandates related to
SO2 emissions.
Mist eliminators are an integral
part of most wet FGD systems, and
the ongoing maintenance and frequent
replacement of these components is to
blame for a large portion of the overall
operating costs of a wet scrubber system. Today, mist eliminators used in
wet scrubber towers are available in
a variety of materials namely polypropylene (PP), fiberglass-reinforced
polymer (FRP), polysulfone, and stainless steel and each has its own distinct advantages and disadvantages.
As discussed in this article, material
selection has a direct impact on both
the operations and maintenance requirements, and the capital and operating costs, associated with mist eliminators used in wet FGD systems.*
While the high-performance, engineering thermoplastic polysulfone is
more costly than other non-metallic
materials, extensive use of this material for wet-scrubber mist eliminators
has been shown to significantly reduce
the number and duration of routine
cleaning cycles, trim operation and
maintenance costs; extend the overall
service life of the mist eliminator com30
Mist eliminators in wet scrubbers comprise a

large portion of system operating costs. Consider
these material selection and replacement criteria
to curb chronic maintenance requirements
ponents; and improve the longterm reliability of these capital- and maintenance-intensive, pollution-abatement
systems. This article presents comparisons between polysulfone and the
other prevailing materials of construction (polypropylene, FRP and stainless
steel) that are routinely used for mist
eliminators, and related brackets and
supports. The article includes data
and anecdotal evidence from three
plants that were surveyed during its
development (Table 1) the Cholla
Station for Arizona Public Service
(APS), Colstrip Montana Station for
PPL Corp., and the Gavin Station for
American Electric Power (AEP). Each
has operating experience with several
of the competing materials.
The diverse operating experience
of these utilities helps to showcase
polysulfones distinct performance
advantages over the other materials, in terms of improved short-term
thermal properties, greater longterm
load-bearing capacity and stiffness at
elevated operating temperatures, and
better resistance to fouling and oxidative attack by the alkaline-scrubbing
reagents and acid gases found inside
the wet scrubber. Common failure
modes associated with the prevailing
materials, such as melting and distortion from loading (polypropylene),
pitting and corrosion (stainless steel),
and delamination and overall degradation (FRP), are also discussed. An
* The findings discussed in this article were first
presented by these authors in a paper entitled,
Mist Eliminators Proper Material Selection
Can Reduce Maintenance Costs and Improve
Reliability in Wet Scrubbers, at the 2006 Mega
Symposium Conference.
economic analysis that illustrates

polysulfones lifecycle-cost advantages over the competing materials is
also included.
Removing acid gases from

post-combustion fluegas
Wet scrubbing is one of the most popular technologies for removing acid
gases, such as SO2 and HCl, from the
fluegas that is produced during coalfired power generation and industrial
combustion-related processes. Wet
scrubbers equipped with mist eliminators are not reserved solely for power
plants; rather, such systems are also
routinely used during industrial operations throughout the chemical process
industries (CPI), to capture acid and
particulate-laden fluegas streams produced by thermal oxidizers, incinerators, boilers, kilns, foundries and other
combustion units, and to treat other
sulfur- or acid-laden process-exhaust
streams produced during various petroleum refining, gas processing, petrochemical, chemical, pharmaceutical
and metals-smelting operations.
The reliable operation of wet scrubbers has a direct impact on a facilitys
ability to ensure regulatory compliance with mandated SO2 limits, and
problems with mist eliminators can
lead to unplanned or excessive downtime of the wet scrubber. Making
matters worse, when backup scrubbing capacity is not available as
was the case with the PPL Colstrip
Station surveyed during the development of this article the resulting
downtime required for mist eliminator cleaning can lead to megawatt
30-37 CHE 1-08.indd 30
12/26/07 5:20:47 PM
Table 1. Relevant details about each of
the three surveyed power plants
Location
Unit number
Generating capacity
Coal used
Cholla Station
APS
Joseph City, Ariz.
2
280 MW
Lee Ranch
McKinley
Gavin Station
AEP
Winfield, W.Va.
1 and 2
2,600 MW
North
Appalachian
Colstrip Station
PPL Corp.
Colstrip, Mont.
1 and 2
716 MW
PRB
sub-bituminous
Table 2. Mist Eliminator Performance Profile

Polypropyl- Vinyl ester FRP PolysulStainless
ene
fone
steel
Relative installed cost
1.0
2.3
2.8
4.8
Melting/softening point* 320F
212260F
365F
2,550F
Oxidative stability
149F
266F
284F
Not a
(longterm temperature)
limitation
Relative ease of cleaning Difficult
Most difficult Easiest
Most difficult
Failure modes
Melting and Delaminating Loss of
Pitting
loss of
and damage ductility
strength
from cleaning
* FRP materials maintain significant mechanical properties above their softening point,
polysulfone gradually softens, and polypropylene forms a viscous melt.
losses, the need to purchase supplemental or replacement power, and

even the possibility of costly service
interruptions at the power plant. (A
more detailed discussion of the financial implications of these megawatt
losses is provided below.)
Inside a wet scrubber, the incoming sulfur-laden exhaust stream is
contacted with a circulating stream
of an alkaline solution (most often a
slurry of caustic reagents). Contact
between the two streams converts
the acid gases in the fluegas into
neutral salts and other solid byproducts (which are eventually removed),
and raises the pH of the fluegas to
78 prior to discharge.
The most widely used reagents are
lime and limestone. With such an approach, a slurry containing calcium
hydroxide or calcium carbonate is
used to convert SO2 to calcium sulfite and calcium sulfate, which then
precipitate out of the solution as a byproduct sludge.
Although several different scrubber configurations are available, spray
towers that use banks of high-pressure nozzles to atomize the scrubbing
liquid into a fine cloud of tiny, reactive
droplets, are the most commonly used,
so the balance of this article focuses on
mist eliminators used in wet scrubber
spray towers. The extraordinary surface-area-to-volume ratio of the droplets intensifies the contact between
the acid-laden fluegas stream and the
scrubbing liquid, and this maximizes
mass transfer of the pollutant from
the gas phase to the liquid and promotes the neutralizing reactions.
Mist eliminators: the basics
Mist eliminators, which are installed

near the top of the spray tower, typically rely on one or more chevronshaped trays or baffles that remove the
fine droplets of the alkaline reactant
slurry that become entrained in the
fluegas stream inside the tower during operation. These droplets typically
contain water, the salt (either unreacted alkali or reacted sulfate/sulfide
compounds), and small amounts of
the acidic gases containing SO2, SO3
and other acidic species that must be
removed from the fluegas prior to discharge from the tower.
Chevron mist eliminators can be
installed and operated in either a
horizontal or vertical orientation. Two
layers are typically used: The first to
remove the bulk of the entrained liquids, and the second to remove residual liquid.
By design, chevron mist eliminators provide a tortuous path for the
fluegas stream, forcing any entrained
droplets to impinge upon the baffle
plates and coalesce into larger droplets, which then fall back into the vessel. These falling droplets mix with
the spray from the slurry nozzles,
creating a mist that promotes intense
mixing between the acid gases and
alkaline reactants.
Additional reactions also occur in
the slurry and byproduct sludge that
collect in the base of the tower. This
byproduct sludge is ultimately dewatered using settling ponds, belt filters,
plate-frame filters or other means, so
that the solids can be disposed, and the
water can be recycled. The returned
scrubbing liquids can be recirculated

for reuse, while the cleaned fluegas
stream is then discharged, essentially
free of mist.
Tough operating conditions
Mist eliminators used in wet scrubbers

routinely experience material buildup
during ongoing operation, and many
of the most widely used mist-eliminator materials suffer from longterm
deterioration in the hot, corrosive and
erosive conditions found inside a typical wet scrubber. In particular, many
of the most commonly used materials
experience the damaging effects of
exposure to sulfuric acid attack over
a wide pH range, in the presence of
fuel-derived chlorides and fluorides.
As a result, proper material selection
is of critical importance to both short
and longterm performance, operations
and maintenance costs, and overall
lifecycle costs of mist eliminators used
in wet scrubbers.
The environment inside a wet
scrubber can wreak havoc on all wet
scrubber internal components, including the mist eliminator and each of
the leading materials of construction
polypropylene, FRP, polysulfone
and stainless steel has a range of
cost and performance attributes. As a
result, proper material selection has
enormous and direct implications for
the overall operation, reliability and
lifecycle costs associated with both the
mist eliminator and the wet scrubber.
Under normal operating conditions,
the temperature inside a wet scrubber
is approximately 130F. However, temperature excursions above 250350F
are not uncommon the result of
upset conditions that can result from
unexpected power outages, problems
with the gas bypass system, clogging
and failure of the slurry piping or
spray header system, or loss of slurry
flow for any reason.
The presence of sulfuric and hydrochloric acids makes the environment
inside a wet scrubber extremely corrosive, and, the presence of flyash,
calcium sulfate, calcium carbonate
and other particulate matter in coalcombustion fluegas creates erosive
conditions inside the wet scrubber. Irrespective of differences in the scrubber reactants used (lime, limestone,
30-37 CHE 1-08.indd 31
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12/26/07 5:21:10 PM
Cover Story
Material selection options
Table 2 provides a summary of the

various material properties, performance attributes and relative cost
differences that are associated with
each of the four mist eliminator materials discussed in this article. In
this section, the primary performance
tradeoffs and limitations of each material in the context of wet-scrubber mist eliminators are discussed,
with illustrative anecdotes from the
surveyed power plants provided later
to showcase the particular capabilities
and limitations of each material.
When specifying particular materials of construction for any type of industrial duty, the anticipated, steadystate operating conditions must be
taken into account. To the best extent possible, any excursions (such as
short-term temperature spikes) that
could occur as a result of potential
upset conditions should also be anticipated and factored in during materials selection.
Polypropylene. Among the four prevailing materials, polypropylene is the
lowest-cost option (on a material-cost
basis), and it is easily formed, molded
and extruded. Polypropylene is also
considered to be a broadly chemically
32
3,000
2,500
PSU
Storage modulus, MPa
flyash or others), or variations in the

sulfur and/or ash content of the various types of coals used, wet scrubber
operators routinely experience both
solids buildup on their mist eliminator components, and a variety of
temperature-related problems during
wet scrubbing.
While insufficient data are available
to determine the impact of the different scrubbing reagents, or the type of
coal, on the fouling of mist eliminator
components, the vast experience of
the utilities surveyed during the development of this article (as well as
anecdotal evidence from many other
customers of the authors various companies) shows that proper material selection has a direct impact on both the
frequency of the solids buildup on the
mist eliminator chevrons, and the ease
and frequency associated with their
cleaning. Proper material selection
can also help to mitigate the thermal
aging problems that typically plague
most wet-scrubber mist eliminators.
2,000
1,500
1,000
PP
500
0
20
70
120
170
Temperature, F
220
270
Figure 1. Shown here is the typical change in flexural modulus as a function of

temperature for both polypropylene (PP) and polysulfone (PSU)
resistant polymer, especially in the face

of both acidic and alkaline constituents
that are found inside a typical wet
scrubber. As a result, polypropylene is
currently the most widely used among
the three polymer-based options for
wet-scrubber mist eliminators.
Fiberglass-reinforced
polymer:
FRP is comprised of a vinyl ester or
polyester resin matrix, to which continuous glass fibers have been added
to provide structural reinforcement.
FRP is widely used in corrosion-resistant piping and vessels due to its low
cost relative to the corrosion-resistant
metals, broad resistance to chemical
attack and corrosion, light weight,
strength, rigidity, and load-bearing
capabilities. The use of FRP for mist
eliminator construction has followed
from its success in other industrial applications.
Polysulfone: This high-temperature
engineering polymer is more costly
than both polypropylene and FRP
from a material standpoint. However,
for use in mist-eliminator applications, a variety of factors help to justify polysulfones premium cost over
the lifetime of the mist eliminator
unit. These include its broad resistance to both oxidation and hydrolysis
in the hot, moist, acidic environment
found inside a wet scrubber, and its
improved retention of flexural modu-
lus, toughness, rigidity and other thermal and mechanical properties at elevated temperatures, compared to the
other polymeric options. (Polysulfones
particular performance advantages in
mist eliminator applications are discussed in greater detail below.)
Stainless steel: Stainless steel is the
most costly of the four prevailing mist
eliminator materials. It is valued for
its superior mechanical strength and
rigidity under prolonged exposure to
elevated temperatures. It is also perceived to be easier to clean, because
its superior mechanical strength allows the operator to use water blasting at significantly higher pressure
to remove solids buildup. However, as
discussed below, stainless steels particular vulnerability to surface pitting
by oxidative attack makes this perception more of a misconception under
real-life, wet-scrubber conditions.
Problems in the field
The types of problems that are routinely experienced with mist eliminators typically fall into two basic categories: Fouling and corrosion; and
heat-related damage to the mist eliminator components.
Fouling and corrosion have the biggest impact on the system operating
efficiency, and on operation and maintenance requirements. Fouling occurs
30-37 CHE 1-08.indd 32
12/26/07 5:21:40 PM
Figure 2. During a test installation,

APSs coal-fired Cholla Station, Unit 2,
installed mist eliminators made from each
of the competing materials (from left to
right: polysulfone, FRP, stainless steel,
polypropylene), in order to compare the
performance of each under identical wetscrubber operating conditions
when solids and salts produced during the wet scrubbing process accumulate on the chevron mist eliminators. Corrosion occurs as a result of
oxidative or chemical attack to the surfaces and crevices of mist eliminator
components, when they are exposed to
hot, moist acid gases in the wet scrubber environment.
In particular, when solids are allowed to accumulate on the surfaces
of the wet-scrubber mist eliminators,
the buildup can close off the available
open area within the chevron baffles.
This leads to increased pressure drop,
raises local velocities in the constricted
passageways, and reduces the collection efficiency of the mist eliminator,
which can result in mist carryover
out of the tower. Such solids buildup
increases the frequency and duration
of cleaning, which brings with it attendant costs associated with extensive
system downtime and maintenance.
Material buildup on the chevrons
can also result in excessive mechanical loading, which can be especially
challenging for mist eliminators and
related connectors and support bracing that are made from several of
the polymeric materials that tend to
lose their mechanical strength when
subjected to the hot, corrosive environment inside a wet scrubber. For
instance, under prolonged exposure
to elevated operating temperatures,
components made from polypropylene
can experience softening and melting.
Coupled with excessive loading from
solids buildup, this loss of thermal
and mechanical integrity can lead to
warping, buckling and the premature
failure of the components. In some
cases, polypropylene mist eliminators
require extra bracing to accommodate
the excessive load on the chevron baffles that resulted from solids buildup
(this was the case for the APS Cholla
power plant surveyed during the development of this article).

Figure 1 compares the modulus of
polysulfone and polypropylene as a
function of temperature. At typical
operating temperatures found inside
a wet scrubber, polypropylene has a
flexural modulus of 2025% that of
polysulfone, which is the material
with the next lowest mechanical properties. In the face of the low modulus
of polypropylene and the high solids
loading, its no wonder polypropylene
mist-eliminator chevrons often call for
additional bracing.
Meanwhile, the wear and tear associated with frequent, high-pressure
water blasting the most widely used
cleaning method coupled with the
thermal aging (described below) work
in tandem to shorten the overall service
life of the chevrons, and lead to more
frequent component replacement.
Cleaning challenges
As noted earlier, once the acid gases in

the coal-combustion fluegas are converted into calcium sulfite and calcium
sulfate during wet scrubbing, these
byproduct solids precipitate and drop
out of suspension, accumulating on the
surfaces and internal passageways of
the chevron mist eliminator. In general, calcium sulfite precipitates as a
soft, white or yellow sludge that is relatively easily washed from any surface
onto which it settles. By comparison,
calcium sulfate tends to form a harder
precipitate. When allowed to settle on
surfaces and in crevices, such buildup
is not only difficult to remove during
routine cleaning operations, but also
adds to surface roughness, which promotes and accelerates further precipitation, calling for even more frequent
cleaning (and related downtime).
To minimize this fouling, chemical
additives, such a magnesium, sulfur
and dibasic acid (DBA), are sometimes

added to inhibit the formation and deposition of such precipitates within a
wet scrubber system. Meanwhile, the
use of spray headers with optimized
spray patterns can also help to minimize the amount of fouling that occurs
during normal operations. However,
neither of these two approaches can
completely eliminate scaling and fouling inside a wet scrubber.
As a result, wet scrubbers with mist
eliminators must routinely be shut
down for periodic manual cleaning.
Periodic-cleaning methods range from
the use of a simple fire hose with the
mist eliminator remaining installed in
the tower, to removal of the mist eliminator components from the scrubber tower so that they can be cleaned
using high-pressure water jets.
Making matters worse, many wetscrubber operators report that the
corrosive and erosive environment
inside a wet scrubber can roughen
the surface of the mist eliminator
components, particularly those made
from polypropylene, FRP and stainless steel. While different mechanisms
are to blame for each of the different
materials, the end result is the same
increased surface roughness that
not only makes the removal of accumulated solids more difficult, but actually accelerates solids buildup over
time, thereby shortening the duration
between required cleanings.
The APS Cholla power plant recently performed an experiment in
which mist eliminators constructed
from each of the four prevailing mist
eliminator materials were installed
in one of the power plants four wet
scrubber towers (a tower that is 80ft tall by 30-ft dia. and housed in the
portion of the facility known as Unit
2; Figure 2).
The photographs shown in Figures
36 provide a visual comparison of the
solids buildup that occurred on mist
eliminator chevrons of each of the
different materials after two months
in service at the APS Cholla facility.
Scale is clearly shown on the polypropylene, FRP and stainless-steel ribs
30-37 CHE 1-08.indd 33
33
12/26/07 5:22:04 PM
Cover Story
(Figures 3, 4 and 5), while the
chevrons made from polysulfone show minimal buildup
(Figure 6; note that in this
photo, solids buildup did occur
on the polypropylene brackets
that are used to support the
Figure 3. Shown here is a polypropylene
Figure 5. During the APS Cholla experipolysulfone chevron blades).
mist eliminator with considerable solids
ment, the buildup on the stainless-steel
Based on its experiments buildup, from the trial installation at the APS
mist-eliminator chevrons occurred mainly
at the edges
comparing the four leading Cholla power plant
mist eliminator materials,
and its favorable operating
experience with polysulfone,
the APS Cholla facility is in
the process of retrofitting its
remaining wet scrubber towers in Unit 2 with mist eliminators constructed from polysulfone, as each of the existing
polypropylene mist eliminators reaches the end of its useful life. Plans are also in the
works to retrofit the existing
Figure 6. The polysulfone mist-eliminawet scrubbers in Unit 1 and
tor chevrons remained largely free of solids
Unit 4 at the same plant with Figure 4. During the APS Cholla trial instalbuildup during the APS Cholla trial, while the
polysulfone mist eliminators, lation, the mist-eliminator chevrons made from supports made from polypropylene did experiFRP
also
experienced
solids
buildup
as well.
ence the telltale solids buildup
The following section contains a more detailed discussion of
When particles are able to become a wet scrubber can also damage mist
how each of the various materials embedded in the polypropylene chev- eliminators composed of FRP, leadfares in terms of solids buildup and rons that have softened under the ing to the formation of cracks on the
surface damage under typical wet elevated temperatures found inside surface, weight loss, and reduction in
scrubber conditions.
the wet scrubber, they create a signifi- bending strength [1]. In particular,
Polypropylene: As noted earlier, cantly roughened surface on a micro- at temperatures on the order of 140
polypropylene is subject to oxida- scopic level. The resulting roughened 160F, and relative humidity in the
tion when exposed to the high tem- surface helps to explain the experience neighborhood of 85% (both of which
peratures inside a scrubber, and of many operators including those are common within a wet scrubber),
often experiences softening at el- at the APS Cholla facility who rou- FRP tends to experience hydrolytic
evated operating temperatures. A tinely report that once polypropylene attack, which weakens the bonds besurface morphology examination of mist eliminators have been put into tween the resin matrix and the glass
used polypropylene and polysulfone service, no amount of cleaning can fibers. Different rates of thermal exmist eliminator components from the ever restore the mist-eliminator chev- pansion and contraction between the
APS Cholla facility, carried out using rons to a good-as-new quality again. glass and resin matrix cause the forscanning electron microscopy (SEM), Instead, polypropylene users con- mation of tiny cracks and voids, which
revealed an interesting finding.
sistently report that after operation increases the potential for delaminaAs shown in the SEM images pro- through an initial fouling and clean- tion. The cracks and exposed glass
vided in Figures 7 and 8, the sample ing cycle, subsequent fouling seems to fibers create a rough surface, which
taken from the cleaned but aged poly- occur more frequently, and that more similar to what is experienced by
propylene mist eliminator chevron is rigorous, more-frequent offline clean- used polypropylene mist eliminators
roughened, and shows the presence of ing must be undertaken to remove the makes it difficult to restore the
embedded particles. To the operators buildup. The operators at APS Cholla, components to a truly pristine condisurprise, chemical analysis indicated when surveyed during the develop- tion during periodic cleaning.
that these particles do not contain ment of this article, summed it up this Polysulfone: When it comes to recalcium thus, they do not represent way: No matter how much we clean sistance to fouling, solids buildup,
a buildup of post-scrubbing sludge. the polypropylene, its never the same and corrosion from acid attack, the
Rather, their composition closely mim- as new packing. It just doesnt func- high-temperature engineering plastic
ics that of the ash found in the McKin- tion as well, even if it looks clean.
polysulfone shows the greatest chemiley and Lee Ranch coal that is burned FRP: As many power plant operators cal/oxidative stability in mist eliminaat the facility.
have found, the environment inside tor applications, compared to both of
34
30-37 CHE 1-08.indd 34
12/26/07 5:22:55 PM
this creates a wet-dry interface

where acidic components can
concentrate [2].
Mechanical and
thermal properties
Figure 7. SEM examination of used polypropylene mist-eliminator sample, 1k magnification
its polymer-based alternatives, and

stainless steel. In particular, polysulfone withstands damage from exposure to mineral acids, alkali and salt
solutions. In numerous utility applications, it shows a considerably longer
service life, compared to polypropylene and FRP, under the range of operating conditions found inside a typical wet scrubber. Meanwhile, because
it demonstrates greater resistance to
the type of surface roughness, pitting
problems and surface buildup that are
commonly experienced by polypropylene, FRP and stainless steel, polysulfone is also the easiest to clean of all
competing mist eliminator materials.
At the APS Cholla power plant, facility operators report they are able to
operate their polysulfone mist eliminators 50% longer than with polypropylene before the unit must be taken
to remove solids buildup from the mist
eliminator (from an average cleaning
frequency of once every three to six
months for polypropylene, to an average cleaning frequency of once every
1012 months for polysulfone).
In addition, when very rapid turnaround is required, the polysulfone
mist eliminators can be cleaned in
situ. However, to ensure complete
cleaning and maximize the duration
between cleaning cycles both the
polypropylene and polysulfone components are typically removed from
the tower. Once they are removed, the
polysulfone components thanks to
their sustained improved mechanical
strength compared to polypropylene
can withstand being cleaned using
more aggressive cleaning techniques.
The removal of the polypropylene
mist eliminators every three to six
months is a brutal undertaking, costing us $100,000 to overhaul and rebuild the scrubber tower each time,
say the APS Cholla facility operators.
By comparison, they note that the
Mist eliminators used during

wet-scrubber service have two
primary mechanical requirements. First, the chevron structures must be able to maintain their
basic shape (not buckling or warping
at elevated temperatures or excessive
solids buildup), in order to allow for a
predictable fluegas flow. In addition,
they must be able to withstand the
high-pressure water blasting that is
required to clean them.
As noted earlier, during operation,
both elevated temperatures and harsh
acidic conditions can compromise
the rigidity, strength and overall mechanical integrity of various materials. When it comes to mist-eliminator
applications in wet-scrubber service,
the ranking of the four prevailing materials by mechanical strength, from
highest to lowest, is as follows: stainless steel, FRP, polysulfone and polypropylene. The mechanical integrity
of each material under wet scrubber
conditions is discussed below.
Polypropylene: As shown earlier in
Figure 1, the flexural modulus and
hardness of polypropylene decreases
significantly with increasing temperature allowing mist eliminators made
from polypropylene to soften, melt and
buckle at elevated temperatures. By
comparison, the flexural modulus of
the other materials remains relatively
constant over the range of normal operating temperatures typically seen in
a wet scrubber.
Because polypropylene melts at
320F, the material is also particularly
susceptible to damage from short temperature excursions that can occur as
a result of temporary upsets in operating conditions. For instance, when
a pump tripped at AEPs Gavin Plant
sending a blast of particularly hot acid
gas through one scrubber, the polypropylene supports (used with its some
of its recently retrofitted polysulfone
mist eliminators) melted.
Similarly, when PPL Montana experienced a blackout that shut down the
water spray nozzles in the scrubbers,
Figure 8. Adhered and embedded particles,

on the used polypropylene mist-eliminator
sample at 3k and 15k magnification
longer duration between cleaning of

the towers that use polysulfone mist
eliminators gives the facility added
flexibility to schedule the necessary
scrubber downtime at a more convenient time (that is, in anticipation of
peak demand seasons).
The APS Cholla operators also
found that solids buildup is so easily
removed from the polysulfone mist
eliminators that the duration of the
cleaning cycle for polysulfone components is roughly 20% less than what
is required for the polypropylene mist
eliminator components.
Stainless steel: As noted above,
stainless steel, while valued for its
improved mechanical strength and
rigidity at elevated temperatures, is
subject to corrosion in the face of the
aggressive conditions found inside a
typical wet-scrubber tower, mainly in
the form of pitting and crevice corrosion. These types of corrosion are well
documented [2] and typically result in
areas where there is a high concentrations of chlorides or other halogens.
Pitting not only increases surface
roughness, which promotes solids
buildup and makes cleaning more difficult, but in extreme situations, it can
also lead to perforations. This was the
case at AEPs Gavin Plant, which is the
largest generating station in Ohio.
That plants two units produce 2,600
MW, and include six wet scrubber towers (each 41-ft dia.). After unfavorable
experience with Type 317L stainlesssteel mist eliminators, AEP has upgraded each of its six wet-scrubber
mist eliminators to polysulfone. According to the AEP facility operators,
after one year of service, the upper
set of stainless-steel mist eliminators
looked like Swiss cheese. The upper
level of mist eliminators is particularly vulnerable to pitting corrosion
because rinse water often does not
reach the top of the upper deck, and
30-37 CHE 1-08.indd 35
35
12/26/07 5:23:25 PM
Percent Retention of Flexural Strength
120
Cover Story
PSU
the resulting temperature excursion

to 400F melted the polypropylene
brackets, while the polysulfone baffles
merely softened. In another incident
at PPL Montana, an operator was
welding and a spark from the torch
ignited the polypropylene brackets.
PPL Montana has since replaced all of
its polypropylene brackets with those
made from polysulfone. Although
polysulfone can burn, it is much more
difficult to ignite than polypropylene,
and is less likely to sustain burn-related damage. Added protection can
be gained by adding flame retardant
chemicals to polypropylene.
In general, the oxidative stability of
polypropylene strongly depends upon
the use of antioxidants added during
the manufacture of the plastic. However, as polypropylene ages, its additives are consumed. Once its additives
are depleted polypropylene materials
tend to fail very rapidly. The rate at
which the additives are depleted is
highly dependent on the environment
operators should be aware that the
hot, moist environment found inside a
wet scrubber tends to accelerate the
aging of polypropylene.
FRP: As noted above, punishing
wet-scrubber conditions can lead to
a loss of bonding between the resin
matrix and the glass mat, which
not only increases surface roughness (contributing to solids buildup
and making FRP difficult to clean),
but also causes FRP mist eliminators to experience a loss of flexural
strength over time. To evaluate the
performance of FRP in comparison to
polysulfone, Solvay Advanced Polymers conducted internal testing of
both materials (using two different
FRP matrix materials). The testing
conditions were designed to simulate
wet-scrubber conditions (exposure to
6,000 ppm sulfuric acid, 1,000 ppm
fuming sulfuric acid, and 1,000 ppm
hydrochloric acid at 210F, for one to
three months). At the end of the testing, the FRP samples had resulted
in a loss of flexural strength ranging from 4080%, while the flexural
strength of the polysulfone samples
was essentially unaffected.
Although the FRP materials were
much stronger than the polysulfone
at the beginning of the test, by the
36
Percent retention
100
80
60
FRP 1
40
FRP 2
20
0
1
Months of exposure
Figure 9. Exposure to acids causes a degradation in the mechanical properties of
many polymeric materials. The laboratory data shown here illustrate the loss of flexural strength over time for both fiberglass-reinforced polymer (FRP) and polysulfone
(PSU) under simulated scrubber conditions
end of the testing cycle, FRP 1 had

approximately the same strength as
polysulfone, and FRP 2 had the same
strength as polysulfone despite
having had an initial strength four
times that of polysulfone at the outset of the test. These test results are
shown in Figure 9. Similar reports
from Reference [1] report a decrease
in FRPs flexural modulus simply as a
result of elevated temperature under
high humidity.
Polysulfone: Thermal-aging data
show that polysulfone demonstrates
greater resistance to thermal aging
compared to both of its polymeric
counterparts (polypropylene and
FRP). For instance, accelerated testing for thermal aging in air that
was carried out at Solvay Advanced
Polymers laboratories shows that
the half life for the tensile strength
of polypropylene compounds ranges
from 1,000 to 2,000 h at a temperature of 302F. By comparison, polysulfone has a tensile-strength half life of
approximately 16,000 h at 338F, a
temperature at which polypropylene
typically melts.
However, over the course of an extended service life, polysulfone misteliminator units may experience a
loss of ductility under hot, acidic
conditions, which can result in some
cracking during cleaning operations,
particularly if the mist eliminator
units are removed for cleaning, and
in many cases, the associated costs
makes polysulfone cost-prohibitive.
Stainless steel: Clearly, stainless

steel outperforms all of its polymeric
counterparts when it comes to inherent mechanical strength and structural integrity under elevated temperatures. However, the corrosion that
commonly results from acid attack
can not only lead to surface pitting
and acid concentrations in crevices
but, over time, can lead to perforation
of the stainless steel chevrons in extreme cases. The major impact of the
pitting is increased surface roughness,
which makes the surfaces more difficult to clean.
Economic considerations
Switching from polypropylene to

polysulfone. After its less-than-favorable experience with mist eliminators
made from polypropylene, (and earlier
experience with FRP and stainless
steel), the APS Cholla facility carried
out an economic analysis to support its
decision to switch from polypropylene
to polysulfone mist eliminators exclusively in Unit 2. As part of that economic analysis, plant operators noted
that each offline cleaning cycle for
polypropylene requiring complete
removal of the chevron baffles from
the wet scrubber, and an offline power
wash carried out by a crew of nine
workers costs more than $100,000
in manpower alone. Based on the ability to cut in half the frequency of its
offline cleaning (from once every three
to six months, to once every ten to
twelve months) by switching to poly-
30-37 CHE 1-08.indd 36
12/26/07 5:24:56 PM
sulfone, the facility is saving $50,000

per tower per year.
An additional justification in APS
Chollas economic analysis was that
polysulfone components do not have
to be replaced as frequently as polypropylene components. Despite the
fact that a polysulfone mist eliminator is two to three times more expensive than one made from polypropylene, it can operate much longer
before it requires replacement. For
instance, at APS Cholla, the polypropylene mist eliminator would be
replaced in less than a year because
the increasing difficulty in cleaning
them made breakage of the chevrons
more prevalent (and the cleaned
components less desirable). By comparison, the polysulfone mist eliminators have already been in service
there for more than three years
something that is unheard of, say
the facility operators. Polysulfones
extended service life and reduced
replacement frequency is currently
helping the utility to realize an additional savings of $13,880 per year
per tower for those equipped with
polysulfone mist eliminators.
The bottom line: When the APS
Cholla facility upgraded the first of
four wet scrubbers in Unit 2 from polypropylene to polysulfone mist eliminators, it spent an additional $52,000 on
the premium components but that
material replacement has saved the
facility more than $146,640 over the
first three years of operation. This represents an ROI of 13 months. As the
operators at APS Cholla said during
the survey conducted for this paper:
Polysulfone pays for itself. Were done
with polypropylene.
Switching from stainless steel to
polysulfone: PPL Montana operates
22 wet scrubbers (six of these 35-ft.dia. scrubbers use polysulfone mist
eliminators, and the remaining ones
use stainless-steel mist eliminators).
When PPL Montana carried out an
analysis to determine the economic
advantages of polysulfone versus
stainless steel for wet-scrubber mist
eliminators, the experience taught
them that polysulfones improved
ability to withstand solids buildup
and corrosion allowed the operators to
take the scrubbers down for cleaning
twice a year, while the stainless steel

mist eliminators must be taken offline
for cleaning eight times per year.
The average cost per 13-h shutdown, in terms of labor, is roughly
$5,000. However, PPL Montana has
no backup scrubbing capacity, so the
downtime required for each scheduled mist-eliminator-cleaning event
also engendered some hidden costs
namely, those associated with a load
reduction of 80 MW. These megawatt
losses have enormous cost implications for the facility. According to PPL
Montana, assuming an energy cost of
$32 per MWh for the 13-h downtime
sessions, the annual MW losses alone
incurred by the towers using polysulfone mist eliminators (taken offline twice/year) cost $76,560, while
the annual MW losses incurred by
the scrubbers equipped with stainless-steel mist eliminators (which are
taken offline eight times per year)
cost the utility $306,240.
As a result, the ability to stem the
MW losses associated with excessive downtime by using polysulfone
mist eliminators instead of those
made from stainless steel is helping
PPL Montana to save $229,680/yr.
And the facility operators note that
if power demand is high, the utility
often has to buy replacement power
during those downtimes, at a cost of
$50100/MW.
Conclusions
Polysulfone, while more costly than

polypropylene or FRP for the construction of mist eliminators that are
used in wet scrubbers, offers demonstrable performance advantages that
can help to reduce overall lifecycle
operation and maintenance costs by
reducing the need for (and duration
of) periodic offline cleaning to remove
solids buildup during operation. Polysulfones longer service life helps to
reduce capital expenditures over the
lifecycle of the mist eliminator.
Meanwhile, polysulfones ability
to maintain its structural strength
and mechanical integrity at the elevated temperatures found inside a
wet scrubber also allows it to compete with costly stainless-steel components, with the added bonus that
unlike stainless steel, polysulfone is
considerably less vulnerable to pitting corrosion under hot, acidic wet

scrubber conditions. It is this type of
surface corrosion that makes stainless-steel mist eliminators so notoriously hard to clean.
Acknowledgements
The authors of this paper wish to

thank Paul Shook of PPLs Colstrip
Station and Frank Fetty of AEPs
Gavin Station, as well as other power
plant personnel, for sharing their extensive experience in the application
of different materials for mist eliminator components in FGD equipment.
We also wish to thank Suzanne Shelley, former CE editor, for her extensive
efforts during the writing and editing
of this article.
Edited by Rebekkah Marshall
References
1. Nishizaki, I., and Meiarashi, S., Long-Term
Deterioration of GFRP in Water and Moist
Environments, Journal of Composites for
Construction, Vol. 6., No. 1., February 2002.
2. Shoemaker, L.E., and Crum, J.R., Experience
in Effective Application of Metallic Materials
for the Construction of FGD Systems, Special Metals Corp.
Authors
Bill Looney is senior global market manager
for Solvay Advanced Polymers, L.L.C. (4500
McGinnis Ferry Road, Alpharetta, GA 30005;
Phone: 770-772-8200; Email: bill.looney@solvay.com) with 25 years experience in high-performance polymers. For the last 15 years he has
worked extensively in helping Solvays customers understand where high performance plastics can be used to replace corrosion-resistant
metals. He earned his B.S.Ch.E from Michigan
Technological University.
Brian Baleno is a business development
representative for Solvay Advanced Polymers
(Email: brian.baleno@solvay.com). Brian has
spent nearly a decade managing material solutions for customers in automotive, aerospace,
chemical processing, healthcare and, of course,
the power plant industry.
Greg L. Boles is FGD Marketing Manager
for mist eliminators associated with scrubbers
for wet-fluegas-desulfurization applications
at Koch-Otto York Separations Technologies
(4111 East 37th Street North, Wichita, KS
67208; Phone: 316-828-5668; Email: greg.boles
@kochglitsch.com). Boles has spent 20 years
with the Koch Chemical Technology Group,
in various capacities of process design, sales,
and marketing. Greg earned his B.S. from Fort
Hays State University and M.S. from Friends
University.
Jacob Tetlow is overhaul planning manager
at the Arizona Public Service Co. Cholla Plant
(P.O. Box 188, M.S. 4455, Joseph City, AZ 86302;
Phone: 928-288-1537; Email: jtetlow@apsc.
com). He is responsible for planning, scheduling and executing overhauls on four coal fired
units. With more than 12 years of experience
in engineering, operations and maintenance,
Tetlow has worked on numerous power plant
projects and overhauls.
30-37 CHE 1-08.indd 37
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Feature Report
Computerized Maintenance Management Systems
For Effective Plant Performance

Corralling gigabytes of predictive
maintenance data isnt easy,
but it's essential for
streamlining your process
Trinath Sahoo
M/S Indian Oil Corp.
Jayantha P. Liyanage
University of Stavanger, Norway
lant maintenance is one of the

disciplines in a chemical process environment that uses
gigabytes of technical and operational data on a daily basis. Of
course, managing an industrial plant
involves a large amount of data,
which can be acquired, stored and
represented in numerous formats for
many different uses (such as financial, safety, sales and maintenance).
How those data can be put to meaningful use for improved plant performance is a common concern in a
majority of these settings. For maintenance management, the primary
challenge is to achieve the proper
balance between plant availability,
process efficiency and equipment optimization. The implementation of a
computerized maintenance management system (CMMS) is one successful way for achieving this goal.
The effective matching of labor and
material resources for maintenance
planning and control is certainly
a dynamic activity. The latest approach has concentrated on supplying managers with reliable information on both equipment performance
and cost, so that they can then make
informed decisions. Thus, it has become essential to adopt techniques
that will provide more accurate and
timely information, making maintenance more meaningful and reducing
unforeseen plant outages.
38
A maintenance management team member takes vibration measurements on a piece of process equipment
Components of a CMMS
Typically, an integrated CMMS needs

to have the following components:
Preventive maintenance planning
Corrective maintenance analysis
Maintenance cost control
Spare parts management
Condition monitoring
To be effective, the CMMS should be
able to call up requested information
from other functions, during any particular function.
Preventive maintenance planning.
Preventive maintenance (PM) planning involves placement of pre-programmed maintenance jobs, available
in the system by default, into their relevant timeslots. Manufacturer-recommended activities that directly contribute to prolonging the life of a machine,
such as lubrication and cleaning, are
carried out under PM planning. Activities that are carried out to assess the
performance of various components at
any particular time also fall under this
subsystem (for example, inspection and
condition-monitoring jobs that are built
into the system for regulatory reasons
or expert recommendations). The PM
planning box (p. 39, left) illustrates the
major content of such a system.
For effective functioning of the PM
planning, the PM master file and the
spare master file must be updated. In
the PM master file, details like the
number of activities for each machine,
their frequency of execution, required
skills, labor time, planned downtime,

spares required, and tools required
are defined. In the spare master file,
spare part details like quantity available at stores, lead time for procurement, reorder level and ordering
quantity, are defined.
Corrective maintenance analysis. Despite the implementation of a
good preventive strategy, surprise or
unwanted failures are unavoidable
in industrial plants. This gives rise to
various corrective maintenance activities. In corrective maintenance analysis, any non-anticipated repair or correction undertaken will be accounted
for and monitored. If the conditionbased maintenance philosophy is in
use, then the repairs can also be taken
on a planned basis depending on the
risk of failure and potential for loss. In
spite of regular condition monitoring
and planned stoppages, breakdowns
are sometimes unavoidable for all
machines due to various factors (fatigue failure, for instance). The maintenance systems efficiency depends
very much on how the system can help
in reducing these unexpected failures.
The main constituents in this module
are briefly discussed in the corrective
maintenance box (p. 39, right).
Maintenance cost control. Maintenance costs generally play a major
role in every industrial facility. Good
control of those costs is essential to
meeting budgetary limits, and even
38-41 CHE 1-08.indd 38
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Some major components of PM planning in Cmms

Weekly PM joBS
A report is prepared in the beginning of a week listing all the PM activities
to be completed. The report is organized on a section-to-section basis for
the users convenience. This report helps maintenance personnel in charge
of each concerned section to plan their work keeping in mind the manpower and other resources available. The production department can also
plan machine shutdown time in advance. The report also indicates the requirement and availability of any specific spare parts or tools that may be
needed for each one of the activities
Work order recording and control
Work orders are prepared for all the jobs listed in the PM report. These work
orders, prepared for each machine and discipline, are sent to maintenance. If
the company is using maintenance software or an enterprise resource planning (ERP) package, then the maintenance personnel can open and check
the work orders on their personal computers. After completion of the job, the
work orders are closed and the total time taken is indicated. The delayed jobs,
when completed, will have annotations regarding the reasons for delay
PM job completion report
This report shows the actual figures, such as labor time and downtime, against
the corresponding plan parameters for all the activities completed in the
course of the week. If some spare parts have been consumed, that is also reported
Pending PM Jobs report
The dynamic situation on the shop floor may force some jobs to remain incomplete at the end of the week. This report will list those jobs that are ongoing at weeks end. The report will be useful in controlling recurrence of such
deviations in the future
UnExecuted PM jobs report
This report points out those PM jobs, which had been scheduled for the
week, but could not be taken up at all. The fluctuation in real-life activity may
force some jobs to be deferred, but such incidents should be kept under
control
Exception report
Exception reports are produced to focus management attention on largescale deviations from the norm. The delayed jobs and the reason for delay
are displayed. The various planning parameters, such as frequency, crew
size, labor and time, may also be indicated for specific activities on certain
machines. The type and context of such reports will vary from plant to plant
depending on the existing system and the environment
to performing posterior analysis for

cost optimization. In the maintenance
department, the evaluation of work
may be done without cost figures as
cost figures are often incorporated and
maintained by the finance department. The evaluation of maintenance
functions, which is based only on
downtime analysis, should be appropriately done by cost figures after converting the time figure to monetary
value. In this process, a maintenance
costing report is generated. The cost of
preventive, corrective and other maintenance activities are typically generated on a quarterly basis. In each category, the costs are shown according to
discipline. The overall performance of
the maintenance department can be
reviewed through this report.
A robust cost-management practice
can also be effectively supported by
planning and estimation. Within industrial CMMS there is support for
such activities, for instance: macroplanning to keep resources in balance
with the workload; system capability
to store, retrieve, modify and copy

previously developed job plans and
estimates from planner libraries;
and ready access to related information when planning a job on a specific
asset without backing out of the planning module.
Spare parts management. For a
successful CMMS, it is essential to analyze the spare parts inventory based
on such issues as annual consumption
value, criticality, lead-time, and unit
price. This is essential since it would
not be possible or effective to exercise
the same type of control for all items.
Common methods are summarized in
the inventory analysis box (p. 41).
Some effective spare-part management information in this context includes: a bill of material components
by equipment; vendors part number
and storeroom item number; reservation of inventory item units to specific planned jobs; prompt processing
of purchase order requests for direct
purchase; and prompt and reliable notification of receipts.
main constituents of a
corrective maintenance
analysis system
Periodic reports
There are two main types of failure reports available, namely Failure analysis reports, and Downtime analysis
reports:
Failure analysis report: the various
faults along with the details like
frequencies of occurrence in each
quarter and the corresponding
downtime involved will be reported
under this heading
Downtime analysis report: this report
is generated quarterly and lists all
the downtime involved in various
categories
Query report
The queries are very useful in elucidating the occurrence of hidden failures,
by generating information pertaining
to the underlying technical issue of
concern. Such a query report can consists of the following:
Maintenance history query: given
the machine number and the reference date, the corrective maintenance history from that date onwards will be indicated in this query
Fault query: given the fault code, the
details about the fault will be displayed for a particular machine or
for the entire plant, irrespective of the
machine
Parts failure query: when the part
number is specified, the details
about the failure pattern will be generated in this query
Downtime query: given the machine
number, all the relevant downtime
details for that machine generated
Condition monitoring. Conditionbased maintenance (CBM) is gaining

more and more popularity as an effective methodology that can be used
as the basis for performing various
maintenance activities particularly
on critical equipment. CBM, in fact, is
the method adopted to monitor and
diagnose the process, machinery and
components of interest. It is applied
largely for diagnosing potential failure
and making a prognosis on the remaining useful life before failure. There are
many machinery parameters that can
be measured and trended to detect the
onset of problems, including the following: machinery vibration, lube oil
analysis (including wear particle analysis), ultrasonic testing, motor current
analysis, infrared thermography, and
bearing temperature.
Condition monitoring serves as a
good decision-support basis for diagnostic and prognostic evaluations.
Trend analysis and online monitoring
can lead to the implementation of robust electronic maintenance solutions.
38-41 CHE 1-08.indd 39
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12/26/07 5:14:10 PM
Feature Report
For example, repair shutdowns can be
scheduled for more convenient times,
and extensive damage to the machine
resulting from forced failure can be
avoided. Repair time can be kept to
a minimum, resulting in reduced machinery downtime. Machines in good
operating condition can continue to
run as long as no problems develop,
saving time and money.
In a plant where thousands of machines and measurement points are
needed, a computerized data-collection
system is generally needed, not only
to minimize data collection time, but
also to minimize data evaluation. For
example, to evaluate machinery vibration a software program is installed in
the computer and a compatible vibration instrument is used for collecting
data in the field. Most systems not
only provide for collecting and trending overall level of machinery vibration, but also offer detailed analysis
software needed to identify specific
machinery faults. After the data has
been collected and downloaded to
the predictive maintenance software,
numerous reports can be generated
to reveal those machines that have
experienced a significant increase in
vibration or have exceeded a present alarm level. A graphic trend may
also be generated by this data. The
maintenance engineer can see from
the graph, how the vibration has progressed over a period of time. Alarm
and trend reports are only a few of the
many reports that can be generated by
condition monitoring software.
Benefits of an integrated CMMS
A well-integrated CMMS solution has

many benefits in a plant setting.
These benefits rely heavily on the integration of technical and operational
data, and those datas effective configuration with the many jobs encompassed by maintenance management.
The ability to increase the efficient
utilization of maintenance resources
while still improving equipment reliability and plant operation time can
be counted among the variety of the
advantages. Due to the avoided wastes
in time and resources (like repetitive
jobs, inconsistencies), an integrated
CMMS can also lead to a lowered unit
cost and increased profitability and
40
ultimately yield improved responsiveness and service towards internal customers and major clients.
Of course, providing decision-making capabilities and support is also a
key advantage, improving control over
PM schedules and documentation.
Spare part inventories are optimized
by identifying demands for parts and
more effective replenishment strategies. Access to maintenance data and
statistics are simplified through report-generation modules for a wide set
of discipline experts. Enhanced communication means job and resource
conflicts are reduced for coordinated
work activities. Ultimately, a CMMS
establishes a good basis for internal
best-practice and the internal standardization of maintenance work.
Choice and implementation
Despite all the potential advantages

and commercial benefits, the choice
of a suitable CMMS, its implementation, and its daily use are still seen
as a challenge by many industrial
sectors. The biggest concern, by far, is
whether an off-the-shelf solution can
be effectively customized so that unnecessary confusion and complexity
are not brought into the internal routines and work practices of either the
decision-making or task-performance
levels. This implies that a professional priority assessment of the need
and impact of CMMS implementation
should to be performed before any investments are made.
Features to look for when selecting off-the-shelf CMMS software.
It would be difficult for any expert to
practically identify and recommend
the best solution given the unique
application features of commercially
available CMMS packages. While it
is by far a choice largely dependent
on institutionally specific factors, in
general, the following five issues are
worth noting in the selection and implementation of CMMS solutions:
1) Maintenance management functionality The CMMS should be made
up of at least four major elements:
an equipment/item registry, work
management, physical assets management and resource management.
The equipment/item registry lists all
the technical components of a facility
by tag numbers. Tag numbers help in

identifying and localizing technical
items. The work management component of the CMMS optimizes dayto-day operations, manages corrective work orders and supports a PM
program for given tags. The physical
asset management component provides quick and easy retrieval of important information such as: planned
and unplanned work history, assets
accounting information, warranty and
service contracts, nameplate data, and
complete descriptive information. The
resource management component of a
CMMS supports a full inventory and
purchasing system.
2) Data mining and management reporting capabilities The underlying
structures for data mining are key to
being sensible and logical in equipment
performance related decision-making
settings. A CMMS should provide extensive and easy-to-use management
reporting capabilities that include detailed and summary reports, as well
as graphical reporting options.
3) PM procedure library The PM
procedure library will minimize the
startup time necessary to establish and
implement your PM program and provide conformance to generally accepted
PM inspection schedules.
4) Multiple system interfaces and data
integration Direct interfaces between the CMMS and other diagnostic and monitoring systems, such as
building automation and PM, can assist greatly in streamlining the maintenance process, by allowing maintenance personnel to respond to early
warning signals before they escalate
into critical repair problems. Inherent
data integration capability is a key
issue in this regard.
5) Proven track record The CMMS
supplier of choice should have fieldproven experience (5 years minimum),
and provide implementation and postimplementation support.
Piece-meal or full implementation.
This is often a million dollar question
with direct conflicts between scale of
internal needs, capital feasibility, and
information technology (IT) capability.
The key question is not, in fact, whether
a piece-meal or full implementation is
necessary, but simply if the requirements have been defined clearly and
38-41 CHE 1-08.indd 40
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Commonly used inventory analysis in CMMS

FSN analysis
FSN stands for fast moving, slow moving and nonmoving items. This form of
classification identifies the items frequently issued, less frequently issued for
use and the items that are not issued for longer periods of time. This classification helps spare parts management in establishing the most suitable storage
layout by locating all the fast moving items near the dispensing window to reduce the handling effort. Also, attention of the management is focused on the
nonmoving items to enable a decision as to whether they are required in the
future or they can be salvaged
SDE analysis
SDE stands for scarce, difficult and easily available. This classification helps in
reducing the lead time required at least in the case of vital items
VED analysis
VED stands for vital, essential and desirable. Criticality of a spare part can be
determined from the production downtime loss due to a spare part not being
available when required. A spare part will be termed vital if, on account of its
unavailability, there will be a very high loss due to production downtime or
a very high cost when the part is procured on an emergency basis. A spare
part will be considered essential if, due to its unavailability, moderate loss is
incurred. A spare part will be considered desirable if the production loss is
not very significant due to its unavailability. VED analysis helps in focusing the
attention of the management on vital items and ensuring their availability by
frequent review and reporting
ABC analysis
In this method spares are classified on the basis of annual consumption value.
Class A: 10% of total spares contributing towards 70% of total consumption
Class B: 20% of total spares accounting for about 20% of total consumption
Class C: 70% of total spares accounting for only 10% of total consumption
In some cases, it is quite possible that many spares will not have been consumed at all in a single year. In such cases, it is better to perform ABC analysis.
The top executive will be interested in having maximum control over the A
items and these should have more than one supplier. Minimum executive control is required for B and C items
properly matched to the capabilities of

the CMMS options.
Because of the strong impact that a
CMMS will have on a service department, it is important that a proper
implementation strategy is developed.
Apart from decisions on the functions
required from a system, it will be necessary to properly manage its installation. Production and service group
training requirements will also have to
be considered. The initial data input,
which in itself can be a huge task, will
have to be planned. If a good company
asset register is available, this will
help. But drawing from experience, it is
likely that even if it does exist, it may
not have been properly maintained.
One of the universal objectives of
any maintenance improvement plan
must be to improve the ratio of planned
versus unplanned work. Clearly, the
ultimate aim must be to move the unplanned maintenance level as far toward zero as possible. In practice, many
unorganized maintenance departments
will have a ratio of 80% unplanned to
20% planned work; much of their work
will be reactive. A CMMS will make the
unplanned easy to monitor and to produce a suitable metric. Over a period it
can be used, along with additional statistics, to reverse the trend.
CMMS and Enterprise Asset Management. CMMS is a mature class

of software that places heavy emphasis on maintenance work management. Depending on the type of
CMMS product, different levels of
sophistication are available, such as
the ability to store inventory and expense information related to the execution of maintenance work. Most
software provides for an inventory of
assets against which work packages
are defined and managed.
Enterprise Asset Management
(EAM) is a newer class of software
that is designed for implementation
on an organization-wide scale. The
term Enterprise means that the
software is part of the core business,
upon which the organization bases financial and management decisions. It
often integrates an organizations financial, billing, customer and human
resource management information.
Many CMMS vendors are enhancing and maturing their product to
be integrated into popular EAM
platforms. Also, many vendors that
have typically focused on the human
resource and financial realms are incorporating CMMS functions to meet
the growing demand for all inclusive
EAM software solutions.
CMMS implementation responsibility. In brief, implementation is a team

effort. What one wants to realize by
implementing a CMMS is the advancement of the maintenance management
workforce to the planned stage of the
maintenance process. It is not the responsibility of only the IT department,
but requires a thorough consideration
of the scale of improvement potential
within the maintenance management
system. For instance, when maintenance engineers see that they have
greater control over stores systems,
they are able to utilize capacity scheduling techniques to better manage
human resources, improving maintenance preparedness. A thorough preimplementation knowledge through
all relevant levels of the organization
is necessary, as well as knowledge of
those who need to bear specific implementation responsibilities. This will
certainly provide a strong basis for
moving forward through the predictive stage of maintenance management to the world class continuousimprovement stage.
Edited by Matthew Phelan
Authors
Trinath
Sahoo
is the
maintenance manager
at
M/S Indian Oil Corporation Ltd., Mathura Refinery
(Mathura Refinery, Mathura281005 U.P.; Phone: 0091565-241-7572; Fax: 0091-565248-0226; Email: Sahoot@
iocl.co.in) where he oversees
the engineering and maintenance related issues of the
refinerys equipment. Sahoo
holds a B.S. in mechanical engineering from University College of Engineering, Orissa. He is the
author of several internationally published papers and has delivered lectures at various global
seminars and conferences.
Jayantha P. Liyanage, is
an associate professor of industrial asset management
at the University of Stavanger (UiS; Faculty of Science
& Technology, University of
Stavanger, N-4036, Stavanger, Norway; Phone: +47 51
83 1440; Fax: +47 51 83 1750;
E-mail:
J.P.Liyanage@uis.
no). He is also the chair and
a project advisor of the Center for Maintenance and Asset Management
(SDV), as well as a member of the R&D group
of the Center for Risk Management and Societal
Safety (SEROS) at UiS. Liyanage holds a B.S.
in production engineering, M.S. in human factors, and Ph.D. in offshore engineering. He has
published more than 75 publications in various
books, international journals and conferences
over the last few years. For his performance he
has received a number of prestigious awards including the 2003 Society of Petroleum Engineers
Best PhD Award and the 2004 Emerald Literati
Club Award for Excellence.
38-41 CHE 1-08.indd 41
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Feature Report
Engineering
Practice
Corrosion Resistance
Using Rock and Glue
Low-cost, corrosion-resistant castings are being produced
using epoxy and mineral aggregates
Terry Capuano
Accures Casting, LLC
tainless steel, painted and plated

cast-iron and steel structures
are being replaced at a fraction of the cost with high-precision polymer castings (PPCs). PPCs
can usually be cast to tolerance, thus
eliminating machining. Because they
are produced from an epoxy-resin material, painting, plating and anodizing
are unnecessary. This reduces the cost
and significantly reduces production
lead time. Polymer castings can be
made in a variety of colors and come
out of the mold with a surface finish as
smooth as that of the mold.
Meanwhile, PPC-pump bases are
claimed to reduce operating noise and
increase the life of the pump bearings
and seals.
Materials
PPCs are made of mineral aggregates

and liquid resin. The resin most often
used in chemical environments is
epoxy. Different grades of epoxy can be
specified, depending upon the anticipated environment. Epoxy resin provides excellent vibration dampening,
excellent chemical resistance, good
mechanical properties and long-term
stability. Additives that improve the
adhesion of the resin to the aggregate
and reduce air entrapment are included in the mixture.
Epoxy resin and hardener require a
stoichiometric mixture, meaning that
the ratio of resin to hardener must be
precisely controlled to assure proper
curing. Volumetric shrinkage is minimal and can be virtually eliminated
through additives.
FIGURE 1.
1VNQCBTFT TVDI
BTUIFPOFTIPXOIFSF BSF
VTFEUPNPVOUDIFNJDBMQVNQTBOE
ESJWFNPUPST5IFZBSFDBTUUPQSFDJTFUPMFS
BODFT TPUIFZDBOCFDBTUBOEVTFEJOUIFTBNFEBZ
5IFZBSFMPXDPTU QSPWJEFFYDFMMFOUDIFNJDBMSFTJTUBODF BOE
EBNQFOWJCSBUJPOXIJDIJODSFBTFTUIFMJGFPGCFBSJOHTBOETFBMTBOE
QSPWJEFTBRVJFUPQFSBUJPO5IFTFCBTFTBSFBMTPVTFEGPSBJSDPNQSFTTPST
XIFSFMPXDPTUBOEOPJTFSFEVDUJPOBSFJNQPSUBOU
There are numerous grades of epoxy

resins and hardeners, so it is important that the correct grade of epoxy be
selected, along with the proper hardener, for the application.
The aggregate, comprising 90 to 95%
of the final composite by weight, is typically high-purity quartz. Quartz offers
excellent chemical resistance and high
strength. High-purity quartz can have
a Mohs hardness of 8, as compared to
diamond at 10. Precisely graded aggregates, from a fine flour to 3/8-in. dia.,
are used to minimize air voids and
maximize mechanical properties.
Painting can be eliminated by the
addition of a colorant, although it is
common to paint the parts when color
matching is desired. A part can be cast
and shipped in a 24-h period, depending upon its inspection requirements.
This provides a significant reduction
in the work in process inventory, as
the time to cast and use a component
is days, instead of weeks or months, as
would be the case for metallic castings
or weldments. The surface finish of
the cast part will be as smooth as the
mold surface. Casting production can
42$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
easily be matched to demand.

Epoxy has also been accepted for
use in food processing applications.
Processing
To make PPCs, resin, hardener and

aggregate are thoroughly mixed, then
poured into an open mold. The mold
is vibrated to reduce air voids and
fill all cavities. The mixture is cured
at room temperature for 4 to 24 h, depending upon the resin system. Some
resin systems are post heat treated for
added strength and stability.
Tapped holes are created by casting
threaded inserts in place, which are
located precisely by the mold. High
precision holes can be cast directly
into the polymer or facilitated via
metallic inserts cast in place. Assembly operations, such as dowel pinning
components, are accomplished by casting a steel block in the area where the
dowel pin is desired.
Inspection of PPC parts is usually
not required, once the locations are
verified, as all of the holes and feature
locations are fixed in the mold. Metallic castings, on the other hand, require
FIGURE 3.#FDBVTFUIFDBTUJOHQSP
DFTTUBLFTQMBDFBUSPPNUFNQFSB
UVSFBOEQSFTTVSF XPPENPMETDBO
CFVTFEUPRVJDLMZBOEFDPOPNJ
DBMMZQSPEVDFMBSHFDBTUJOHT5IJT
JTBQIPUPPGBNPMEVTFEUP
QSPEVDFB MCQSPDFTTJOH
NBDIJOF5IFESBJOQJQFTBSF
DPNNPO17$QJQFT XIJDI
HFUDBTUJOQMBDF
FIGURE 2.
5IJTQIPUP
TIPXTBDIFNJ
DBMMZSFTJTUBOU
USFODIESBJO
VTFEJODIFNJ
DBMQSPDFTTJOH
QMBOUT GPPE
QSPDFTTJOH
QMBOUTBOE
BMPOHESJWF
XBZTBUHBT
TUBUJPOT5IFTF
ESBJOTDBQUVSFUIFPWFSGMPXPGQSPDFTT
DIFNJDBMTPSXBTIEPXOXBUFSJOTJEF
QMBOUTUPNBJOUBJOBDMFBOBOETBGFFO
WJSPONFOU0VUEPPSTUIFZBSFVTFECF
DBVTFPGUIFJSSFTJTUBODFUPGSFF[FUIBX
DZDMFTBOEUPTBMUEBNBHF5IFZBSF
FQPYZQPMZNFSDBTUJOHTBOEUIFSFGPSF
SFTJTUNPTUDPNNPODIFNJDBMTBOEBSF
BMTPBDDFQUFEGPSDPOUBDUXJUIGPPECZ
UIF64'PPEBOE%SVH"ENJOJTUSBUJPO
individual inspection, as machining

operations can vary due to tool wear,
tool breakage and positional errors.
The wall thickness of PPCs can
vary without inducing any internal stresses. Ways precise surfaces that machine components slide
against can be mounted directly to
the polymer surface. If low cost tooling is used, the ways can be grouted
into precise location or steel segments
can be cast in and post machined.
Tooling
The polymer-casting process takes

place under ambient atmospheric
conditions. This offers the significant
advantage of allowing the use of lowcost molds. Prototype molds can be
produced from wood, sheet metal or fiberglass. Simple prototype parts, even
parts weighing thousands of pounds,
can be cast in a matter days.
Wood molds can be used for casting
simple parts in low quantities. Fiberglass molds can be produced using
existing parts as the model, saving on
pattern and mold-design costs. With
proper handling, hundreds of parts can
be expected from a fiberglass mold.

A heavy-duty steel mold must be
used to cast parts precisely. Mold design and construction are critical to
produce repeatable tolerances, with
the minimum production time. A poor
mold design or construction will result
in inconsistent tolerances, slow production, poor cosmetics and the need
for secondary operations.
The casted material exactly replicates the mold, so the surface of the
finished part will be that of the tool.
A highly polished mold will result in
a highly polished part. A mat finish or
cross hatching in the product can be
achieved by applying the desired surface to the mold.
Properties
Machine components can be repeatedly cast flat to 0.0005 in./ft, hole diameters to 0.0001 in./in. and feature
dimensions to 0.0005 in./ft. Whereas
iron castings require the production of
a rough casting, followed by precision
machining, with stress relief before
and after, and painting, PPC parts
are simply cast to tolerance, demolded
and used in the assembly. A precise
iron casting may take four months or
more to produce, while a polymer casting can often be produced and used in
days. Since the parts will not rust or
corrode, painting is not necessary.
It is possible to cast integral surfaces with uniquely different properties. A grinding-machine way surface
is cast using a low-friction polymer
material when the part is cast. The
way surfaces use a low-friction epoxy
formulation that provides high lubricity and long life. Castings can be made
to be magnetic, electrically conductive,
heavy or light.
Casting at room temperature allows the use of plastic or cardboard
tubing to produce wire ways, vacuum lines or drainage holes. Using
standard 4-in. dia. polyvinylchloride
(PVC) tubing, high-flow coolant lines

are cast in place in a grinding machine. A digital scanner base requiring 161 vacuum lines is cast using
standard vinyl tubing attached to
the sides of the mold and left in
place when the casting is demolded.
The 0.001-in. TIR (total indicator
reading) of the 18-in. dia. surface is
unaffected by the vacuum lines.
Although the 15 to 30% lower cost
of a PPC is important to most users,
the primary reasons for switching to
a PPC base are vibration dampening
and chemical resistance. Some machine-tool manufacturers have claimed
cutting-tool-life increases of up to 30%
and smoother machined surfaces.
High-speed printing machines and
scanners enjoy better resolution at
higher speeds due to the vibration
dampening. PPCs tends to dampen vibration 10 times better than cast iron
and 45 times better than steel.
Applications
PPCs have been used in the following

applications:
Chemical pump bases
Food-processing equipment
Electrolytic tanks
Pulp-processing equipment
O
Edited by Gerald Ondrey
Author
Terry D. Capuano, P.E.,
is founder and president of
Accures Casting, LLC (140
Greentree Rd., Moreland
Hills, OH 44022; Phone: 440343-0461; Fax: 440-247-2293;
Email: TDCapuano@aol.com),
as well as president of TED
Properties, LLC, Teneric, LLC
and the Capuano Foundation,
which is dedicated to helping
children. He has over 25 years
of executive management experience, more than
30 patents and was the youngest vice president in two different 100-year-old companies.
Among his many notable accomplishments are
the startup of the first polymer concrete casting
company in the U.S., and the development of a
number of polymer composites and the Zanite
composite-casting technology. Capuano holds an
AASME degree from Waterbury State Technical
College, a BSME (with honors) from Tri-State
University, and an MBA from Rensselaer Polytechnic Institute.
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:43
Feature Report
Engineering
Practice
Seal-Fluid-Circulation Devices:
Understanding the Differences
Knowing the options in
fluid-circulation designs
helps in the
selection process
API-682 states
1.5 mm (0.060 in.)
minimum here
Alan Roddis
Aesseal plc.
ver the past few decades, hundreds of seal geometries and a fair
number of seal categories have
evolved. Recently, the distinction
between single- and dual-mechanical
seals has been brought into focus by
heightened safety and environmental
concerns. Dual seals are often selected
where safety is of paramount concern.
To aid in selection, an understanding of
how the fluids used in these seals are
recirculated is important.
Convection or pumped
circulation?
Mechanical seals are typically used to

prevent leakage from the fluid side of
pumps into adjacent bearing housings
and to the environment. In dual-mechanical seals, a barrier fluid generally a liquid is applied to the space
between the two sets of seal faces
and is either moved around slowly by
thermal convection, or it is pumped
through a heat-exchanger loop. Of the
two methods, barrier-fluid movement
by convection (or thermo-siphon action) is the least effective. When a dynamic-pumping action is imparted to
the barrier fluid within the mechanical seal, more fluid is moved and more
heat is dissipated per unit time.
The benefits of using pumping rings
or devices resembling a helical screw
for barrier-fluid circulation in dual
seals derive from the fact that thermal
convection is a slow process and that
its cooling action is somewhat difficult
to predict. It is desirable to keep sealface temperatures relatively cool and
44
sufficiently below the point of vaporizing the liquid film between the faces.
Cooler operation is an obvious risk-reduction step, which explains why sealcirculation devices have generally
been well received in industry.
Circulation-device standards
The path towards innovation and reliability differs from one manufacturer
to another, and so several types of circulation devices are currently available. It is important to know fundamental differences between the major
circulation devices in order to select
one for a given application, and it is
also helpful to understand the best
practice information contained in
the API-682 Standard on Mechanical
Seals. This API standard represents
the collective experience of industry
experts in rotating equipment and
mechanical sealing.
Section 8.6.2.3 of the latest API-682
standard, which outlines best-practice
mechanical-seal design, specifies a
radial clearance of 0.062 in. (1.5 mm)
between rotor and stator components
(Figure 1). Just as with impeller wearring clearances, this minimum clearance for seal components is based on
long-term rotating equipment experience. The potential consequences
of metal-to-metal contact are well
known and, more specifically, rubbing
of rotating stainless-steel components
against stationary parts can lead to
serious galling. Such galling and even
seizing is possible if internal seal
clearances are too small and align-
FIGURE 1. For seal-fluid

pumping devices, such as
this parallel helical-vane
(screw-thread) unit, API682 recommends clearances to reduce risk of
contact between rotating
and stationary parts. Unfortunately, some vendors
tighten up the clearances
so as to gain efficiency
ment is not perfect. Out-of-alignment

conditions are not unusual and are
often the result of pipe stress or weak
baseplate supports.
Not all mechanical-seal manufacturers, however, conform to the best
practice recommendations. This can
lead to increased safety and reliability
risks. It is not unusual to see vendor
bids that state that a product conforms
to API-682, except for such and such.
Printed in small, sometimes hardto-read text, one may find the words:
which change the radial clearance of
the circulating ring and stator.
So, why would a seal manufacturing
company deviate from best practice,
especially if it had contributed to the
recommendations found in API-682 in
the first place?
At issue is the fact that application
engineers have two sets of competing
requirements. One is to make the radial clearances safe and contact-free.
The other is to ensure that the flowrate
of the circulation device is sufficient to
overcome the seal and support-system
resistance, and to effectively remove
heat from the seal. It is thus left to the
ultimate equipment owner-operator to
examine the pros and cons of the available alternatives.
Circulation systems
Being able to visualize the principal

devices that are available will assist in
selecting the most advantageous sealfluid circulation device:
Parallel helical vane (screwthread). This device (Figure 1) is
44-45 CHE 1-08.indd 44
12/26/07 5:07:09 PM
100 mm (4-in.) seal with API-682 radial clearance-head-flow characteristics for various circulating devices on oil at 3,600 rpm
0
0.5
Flow, U.S. gal/min

1
1.5
2
125
Head, mm water
3,000
2,500
FIGURE 3.5BQFSFE
WBOFQVNQTIBWFPQUJ
NVNQFSGPSNBODFBOE
BMPXSJTLPGDPOUBDU
CFUXFFOSPUBUJOH
BOETUBUJPOBSZ
DPNQPOFOUT
typically supplied as a unidirectional

component, meaning that it will only
work with the shaft rotating in one direction. Parallel helical-vane devices
demand a close radial clearance between rotor and stator (often 0.010 in.
or 0.25 mm) and operate similarly to a
progressive-cavity pump. This design
does not perform well with radial gaps
of 0.062 in. (1.5 mm) as dictated by the
API-682 specification, because fluid
slippage increases exponentially as
the radial gap increases linearly.
Parallel slot or castellations. This
device (Figure 2) contains a series of
parallel slots around the circumference of a rotating member and is bidirectional as it will work irrespective
of shaft rotation. It circulates fluid by
throwing the fluid towards an outlet port and imparts centrifugal force
through the rotating action of the
slots. This means that the circulating
device must be positioned directly opposite the barrier-fluid outlet orifice,
otherwise it will not work. In addition
to this constraint, another issue with
this design can be seen in Figure 2
the fluid is not effectively kept in
motion at the inboard faces. As the ra-
75
1,500
50
Screw thread
1,000
500
0
FIGURE 2.1BSBMMFMTMPUPSDBTUFMMBUJPOUZQFQVNQJOHEFWJDFT
BSFMFTTFGGJDJFOUUIBOPUIFSNFUIPETUPNPWFTFBMJOHGMVJE
100
Tapered vane
2,000
25
Parallel slot
0
4
Flow, L/min
Head, inches water
3,500
FIGURE 4.*OUIJTDPNQBSJTPOPGIFBEBOEGMPX OPUF

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FST BMMPGXIJDIIBWFNFDIBOJDBMTFBMT
dial gap between the rotor slots and

stator increases, the pumping rate of
the design decreases dramatically because of fluid slippage.
Tapered vane. The tapered vane
(Figure 3) includes a series of vanes
around the circumference of the rotor.
The vanes are angled in two directions, hence the device is fully bidirectional. It will circulate fluid irrespective of the shafts direction of rotation.
Both rotor and stator have an inclined
surface that redirects the fluid centrifugal force induced from the rotating action of the slots into an axial
force. This means that the circulation
device is not dependent on maintaining a close radial clearance between
the rotor and stator. Furthermore, it
means that the device can be placed at
any axial position between the inboard
and outboard seal faces. Therefore,
fluid can be effectively replenished at
the inboard seal faces, keeping the primary seal faces cooler and tending to
extend seal operating life.
Comparing the designs. A comparison of the head-to-flowrate trends of the
three pumping-ring designs discussed
above is shown in Figure 4. Testing
was done on each using the same seal

and in the same barrier-fluid system,
with oil as the barrier fluid. In all cases
the radial clearances between stator
and rotor conformed to the clearance
stipulated by API-682, Section 8.6.2.3
(0.060 in. or 1.5 mm).
These tests provide ample evidence
that excellent barrier-fluid flowrates
can be achieved using the taperedvane design, without risking touchoff between close proximity rotating
components and surrounding stationary parts in older-style seal-fluidcirculation devices. This design thus
adheres to the safe operation outlined
in API-682 without compromising desired head-to-flow characteristics.
Being aware that many thousands
of these innovative tapered-vane circulation devices have been in successful
use since the early 2000s, seal users
are encouraged to consider this highly
effective pump-reliability upgrade option. Be on the lookout for outdated
technology and understand the potential impact of non-conformance clauses
in a vendors proposal.
O
Edited by Dorothy Lozowski
Author
Alan Roddis is the engineering director of Aesseal
plc. (Mill Close, Rotherham, U.K. S60 1BZ; Email:
alanr@aesseal.co.uk) He is a
graduate mechanical engineer
(honors degree) and has been
responsible for the design of
modern sealing devices used in
pumps, mixers, compressors,
steam turbines, gear speed
reducers and dozens of other
machine categories used by hydrocarbon processing, power generation, pharmaceutical, mining,
food processing, paper, and many other industries
in dozens of countries. Roddis holds several U.K.
and international patents on advanced sealing
products and related mechanical devices. In his
position at Aesseal, he continues to spearhead the
design and development efforts at this manufacturer of advanced technology sealing products.
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:45
FOCUS ON
Mixers
Less balling of dry powder with this mixer

Outfitted with three independent agitators, the Triple
Action Disperser promises
a low energy and fast
method for mixing highquality dry powders into
liquid dispersions. Its design allows for a controllable vortex and powder
wetting, preventing the
balling typical of powders on liquid surfaces. The
disperser is available in
350 to 20,000 L capacities
with a vari-batch model
featuring 25% operating
capability.
Constructed
in the consumers choice of carbonsteel, stainless-steel or special alloys,
the vessel can be purchased as a flattop tank with opening sections and a
conical base or a vari-batch dished top
tank including a deep conical base for
emptying viscous products. Heating or
cooling jackets, to PD5500:2003 Category two applications and internal
pressure or vacuum add-ons are also
available. The firm states that the
device has high viscosity and specific
gravity capabilities. Joshua Greaves
and Sons Ltd., Bury, England
Achieve short residence times
with this mixer
A new sanitary, continuous, rotary
mixer Model 16-4SS (photo) can
homogenize material ratios as disparate as 1 ppm, with 100% uniformity
according to the manufacturer. The
device furnishes the uniform mixtures
gently and in short residence times: 1min for a 2.45 m3/h capacity and 2-min
for a 1.19 m3/h capacity. A large-scale
option is also offered, with diameters
up to 152 cm, lengths up to 457 cm,
and capacities of 121 m3/h at a 1-min.
residence time and 59 m3/h at a 2-min.
residence time. The mixers forwardand reverse-pitch, back flow mixing
action and rotating cylinder with proprietary mixing flights have been de-
Munson Machinery
Sharpe Mixers
signed to eliminate the internal plugging or accumulation of materials. Its

smaller drive motor operates at 0.5 hp
(0.37 kW). The large-scale option motor
reaches 20 hp (14.92 kW). Drum angle
and rpm can be adjusted. Dust-tight
diaphragms at both the intake and
discharge ends prevent the escape of
dust or fumes. Material contact surfaces are made of 316 stainless-steel
finished to sanitary standards, though
carbon steel, AR-235, 304 stainlesssteel and specialized materials, such
as Duplex-stainless and Hastalloy,
are available as alternatives. The firm
also offers an optional internal stainless-steel spray line with spray head,
for the uniform introduction of a liquid additive. Munson Machinery
Co., Inc., Utica, N.Y.
Mix multiple tanks easily with
this air-operated stand
Suited for applications where the number of requisite mixing tanks vary, the
ALS-Series of Air-Lift Mixer Stands
(photo) features an air-operated hand
pump for the efficient raising and lowering of its mixer shaft into a tank. The
portable device is especially useful in
pilot plants and laboratories where
shifting mixing requirements often
necessitate multiple portable mixers.
The ALS-Series comes in three stroke
46$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
sizes, 36-, 48- and 60-in., and either

epoxy-painted steel or stainless-steel
construction. Several optional features
are also available, including a fullyadjustable, tank-positioning arm; 2-in.
wide, nylon, ratcheting tank strap; adjustable leveling guides; chrome plating; locking casters; counterweights;
and a height-lock positioning collar.
Price quotes from the firm are approximately $3,000 and up for the mixer
stand, depending on the construction
and options selected. Sharpe Mixers,
Seattle, Wash.
An oversized shaft makes this
agitator less noisy, more efficient
The Model 20 HT/GT agitator (photo,
p. 47) boasts a gearbox designed specifically for agitator service; right
angle (HT) and parallel shaft (GT)
configurations; and a modular design
that reduces the replacement-part
inventory typically required by consumers. Its oversized output shaft
extends the life of its bearings and
gears while reducing gear deflection
and noise, lowering maintenance costs
and improving productivity compared
to general purpose gear-drives with
the same nominal AGMA torque rating. (In addition to AGMA, the Model
20 HT/GT meets OSHA, ANSI, IEC,
DIN, EU and ATEX standards and

Charles Ross & Son
Chemineer
requirements.) The manufacturer offers a range of seal options including a

spring-loaded, nitrile-rubber lip seal;
a split mechanical seal, with a twopiece design for simplified installation
and maintenance; single- and double-mechanical seals; and a six-ring
stuffing box that utilizes standard
PTFE/graphite-braided packing and
requires no lubrication. All seal options have quick and easy seal-change
capability, according to the firm, and
include features to mitigate the risk of
lubricant leaking down the shaft. With
a wide range of speeds available, and
a reversible rotation option, the firm
says that their agitator is designed
for broad service in the chemical,
pharmaceutical, ethanol and biofuels,
water and wastewater, FGD, power
and other general process industries.
Chemineer, Inc., Dayton, Ohio
jars with 5 or 10 reaction vials. Digital settings for the grinding time and
vibration intensity, as well as storage
features with up to 9 parameter combinations, ensure reproducibility of
sample preparation. Retsch GmbH,
Haan, Germany
This lab mixer mill works dry,

wet and cryogenically
The Mixer Mill MM 400 is suitable for
homogenizing up to 20 small sample
volumes simultaneously. The devices
two grinding stations can process materials as disparate as tablets, minerals, bones, tissues, soils and plastics
down to 5-m granules, depending on
the substance. Its screw-top grinding
jars are leak-proof for 100% material
recovery during wet grinding. They
are also capable of cryogenic grinding. The jars are available in sizes
ranging from 1.5 to 50 mL and can
be made from six different materials. Among the optional accessories
are adapter racks substituting the
ber
A single planetary mixer for

high-viscosity paste materials
Available at capacities ranging from 1
to 300 gal, this new single planetary
mixer (photo) is equipped with a custom helical mixing blade which allows
for the mixing of high-viscosity pastes.
The device boasts a 316 stainless-steel
construction with a 150-grit finish,
a dished-bottom mixing can and a 6in. flush discharge valve. Its NEMA 4
control panel (which has been purged
for Cl.1 Div. 1 hazardous areas) and
dust tight design promise safe operation and compliance with national
(U.S.) standards. The new mixer comes
outfitted with charge and sight ports,
caster wheels and an air/oil hydraulic
lift for raising and lowering the agitator from the mixing vessel. The firm
offers optional jacketed mixing vessels
and vacuum construction. Charles
Ross & Son Co., Hauppauge N.Y.
Matthew Phelan
A d v a n c e d P r o c e s s S o l u t i o ns
LEADING WORLDWIDE IN MIXING TECHNOLOGIES
The EKATO GROUP provides their customers with the technical excellence and
experience of a global market leader. The companies within the EKATO GROUP
operate across the spectrum of mixing technologies.
From simple laboratory mixers to turnkey production plants, the EKATO GROUP provides a range of
engineering services and custom-made solutions for the most challenging customer applications. The
synergies within the EKATO GROUP ensure that reliable and cost-effective solutions can be provided
to the highest quality standards for every application. This is supported by a global service network.
Your contact in Europe

Tel.: +49 7622 29-0
e-mail: info@ekato.com
GROUP
www.ekato.com
Your contact in the USA

Tel.: +1 201 825 4684
e-mail: ecorp@ekato.com
46-47 CHE 1-08.indd 47
47
12/26/07 5:53:14 PM
Solids Processing
Operations
& Maintenance
Technology and Scheduling:
The Perfect Chemistry

By utilizing efficient scheduling software,
companies in the CPI can improve
enterprise agility and compliance
Rory Granros, Infor
n the fast-paced and ever-changing world of chemical processing,

companies are constantly trying
to keep up with the latest technology, while at the same time creating detailed schedules that enable
them to maximize customer service,
enterprise agility and compliance, and
minimize inventory, changeovers and
overtime.
Process manufacturers need to ask
several questions when evaluating the
impact of scheduling software on efficiently managing plant capacity and
product throughput.
Are orders sequenced in a way that
best uses production resources?
Is it known when production should
be offloaded to alternate resources?
Can the impact of a supply shortage
on fill rates be evaluated?
Does the effect of unplanned production and downtime need to be
minimized?
Does revenue growth need to be
supported using existing production assets?
Managing a complex mix
With the use of volume-based assets,

such as tanks, the production process
becomes extremely complex compared
to other resources. The unique and
complex characteristics of tanks make
it difficult to schedule them accurately,
especially under capacity pressure.
For example, tanks process one formula at a time, are connected by pipes
and may need to be cleaned between
batches. These are all characteristics
that complicate their use.
Many organizations still schedule
production runs manually. With product proliferation and shorter leadtime,
48
this greatly limits visibility into the

complete manufacturing operation. As
a result, these companies are unable
to take maximum advantage of potential production efficiencies.
Other factors, such as different in
and out flows, material constraints
and variable processing times, make
the schedulers task of determining an
optimal schedule nearly impossible.
In order to effectively schedule volumes, manufacturers need technology
designed for the unique needs of the
chemical processing industries (CPI).
Manufacturers require scheduling
software that can effectively manage
these complexities and maximize production and staff, virtually eliminating disruptive changes in the scheduling process.
How quickly can you react?
Optimized tank scheduling is essential for improving agility and flexibility, as well as maximizing utilization
and throughput of manufacturing facilities. Companies without scheduling technology lose a great deal of opportunity because they cannot quickly
react to changes in the production environment. When evaluating scheduling software, it is essential for manufacturers to identify products that can
dynamically schedule the intricacies
of tanks while simultaneously taking
into account the constraints and processes of their plants.
With visibility into constrained resources and bottlenecks, a company
can adapt schedules that address these
issues more quickly. A comprehensive
scheduling solution should provide 24hour access to view realtime schedules
and reports via the Web, which allows
Figure 1. Scheduling is complicated by

tanks and other volume-based assets. Efficient
scheduling software will effectively manage
these complexities by increasing production
while eliminating unnecessary downtime
them to perform what-if analyses

and run multiple scenarios to test the
feasibility of a campaign or batch before beginning production. The added
visibility provides capabilities for
longterm production planning and results in significant value. The added
flexibility to quickly make modifications and schedule changeovers, while
at the same time linking dependent
processes, results in reduced complexity and increased throughput.
Timing is everything
A common problem occurs when

scheduling systems treat tanks like
discrete manufacturing resources. In
this case, a historic average or common duration is used to determine the
effective rate or duration. However,
real occurrences often differ from the
historic value, resulting in an over or
under estimation of the tank capacity and timing errors for resources
that are feeding to or from the tank.
The issue is compounded over time as
these errors reoccur and simply create
more unusable schedules.
A scheduling solution must be
able to manage independent inflows
and outflows that vary with material, resources or other constraints.
It should also allow for delays or
standing time between inflow and
outflow. In addition, solutions that
can account for storage constraints
and handling finite capacity are far
more effective at managing volumeconstrained resources.
Buffers, capacity & changeover
Understanding buffers is critical to

achieving maximum throughput for
a chemical manufacturing facility,
48-49 CHE 1-08.indd 48
12/26/07 5:50:02 PM
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and scheduling solutions must effectively manage all of these various

buffer characteristics. In addition,
scheduling solutions should include
a single buffer to perform all the
functions simultaneously.
Routing and product constraints
are also common in tank scheduling; however, they can be handled
efficiently when using a scheduling
solution that accounts for simultaneous feeding and consuming resources,
connection and product-dependent
constraints, and multiple flowrates. A
solution that can manage these limitations and constraints will enable a
company to determine capacity more
accurately and develop optimal production schedules.
When looking for a scheduling solution, it is important to consider
changeovers and how to manage them
in order to create feasible schedules.
For example, storing a low-quality
product after a similar high-quality
product may require little cleaning,
while the opposite order may require
extensive cleaning.
One simple and commonly used, yet
ineffective, method is to supply historic changeover values from product
to product. Unfortunately, this approach leads to enormous changeover
matrices that require heavy maintenance. Scheduling solutions that are
specifically designed to handle the
intricacies of tanks are able to supply
values that actually cause the changeover, such as color, quality, brand or lot
number. As a result, visibility is improved, allowing engineers to react to
current conditions.
To maximize plant utilization, decisions about tank and batch sizes need
to be carefully considered. Future
batch requirements, such as due dates
and quantities, should also be part of
the equation. By considering capacity
and providing dynamic batch sizing
capabilities, a software solution with
advanced tank-scheduling capabilities
will create an optimal schedule, allowing the best utilization of the plant
without adding additional costs.
Tank grouping
& product changes
An effective scheduling system can

dynamically determine which products go in which tanks, in what batch
sizes, and at what times based on current conditions and constraints. An
effective solution will also be able to
flexibly group tanks and products to
support the scheduling process.
Product changes are critical to the
scheduling process because the outcome of physical checks or quality
assurance determines when outflow
can begin and, ultimately, when the
product can be produced. As the state
of the product changes, the schedule
needs to be adjusted accordingly. If
succeeding batches on a tank must
begin sooner or be delayed, the entire

schedule needs to be quickly and easily adjusted. When scheduling tanks,
constraints caused by changes to the
product must be dynamically calculated since the duration of the batch is
both schedule and qualification dependent. The right scheduling solution will
take into account that what goes into
the tank is not always what comes out
and will allow for easy adjustments to
accommodate these changes.
Business-specific solutions
By taking control of its production

scheduling, a company can maximize
shop-floor throughput while optimizing resource investment. As a result,
the organization will be able to optimize critical resources, calculate and
execute realistic and feasible schedules, and easily determine the schedule that best meets its objectives. O
Edited by Kate Torzewski
Author
Rory Granros is the director
for industry and product marketing for process industries at
Infor, a leading global provider
of enterprise software (1356 Morris Road, Suite 4100, Alpharetta,
GA 30004; Phone: 678-319-8000;
Fax: 678-319-8682; Email: rory.
granros@infor.com). With more
than 25 years experience in developing and marketing innovative
PLM, ERP and decision support
solutions, Rory Granros leads the global marketing
initiatives for Infors industry-specific process manufacturing capabilities including PLM, ERP, SCP, SCE,
EAM and CPM. For more information, please contact
inforinfo@infor.com.
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Stainless Steel
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(973) 256-3000 Fax: (973) 256-4745
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High Pressure
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Intelligen Suite
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the world (including 18 of the top 20 pharmaceutical companies and 9 of the top 10 biopharmaceutical companies).
SchedulePro is a versatile finite capacity scheduling tool that generates feasible production schedules for multi-product facilities that
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Visit our website to download detailed product literature

and functional evaluation versions of our tools
INTELLIGEN, INC. 2326 Morse Avenue Scotch Plains, NJ 07076 USA
Tel: (908) 654-0088 Fax: (908) 654-3866
Email: info@intelligen.com Website: www.intelligen.com
Intelligen also has offices in Europe and representatives in countries around the world
51-56 CHE 51-56.indd 51
12/26/07 5:56:16 PM
SOFTWARE
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Email: hhicks@che.com
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centrifuge GEARBOXES
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Wabash Sells & Rents

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New ARRIVALS for FALL- BIOPHARM

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500 liter Vertical Agitated BioPharm Pressure Vessel, 316L-S/S
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Yamato Model GB-21 Pulvis Fluid Bed Dryer
Yamato Model GB-22 Pulvis Fluid Bed Dryer
100-N Applied Chemical Laboratory Fluid Bed Dryer, S/S
196- S Quadro CoMill, Sanitary Type 316 Stainless Steel
Model W-750-H Greerco Horizontal Colloid Mill, 316 S/S
Model SD-5 Charlotte Horizontal Colloid Mill, S/S
Shionogi #10 & Macofar CD-40 Capsule FIllers
300 ml.., & .5 Liter Netzsch Media Mill
1 qt.,2 gal., 4gal, 50 Ross LDM & PVM Mixers, S/S, Vacuum , Jkt. (6)
5000 Gal. Vertical Agitated, Tank, 304 S/S (2)
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in the
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Product Showcase
and
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Tel: 212-621-4958
Fax: 212-621-4976
Consulting
Classified
KnightHawk
Engineering
Specialists in design, failure analysis
and troubleshooting of static
and rotating equipment
Computational Fluid Dynamics
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Heat Transfer Analysis
Vessel/Exchanger/Machine Design
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Pelletizing Die Design
Process Simulation
Pipe Stress
www.knighthawk.com
Tel: 281-282-9200
Fax: 281-282-9333
54

Tel: 212-621-4958
Fax: 212-621-4976
CRYSTALLIZATION & PRECIPITATION

Dr. Wayne J. Genck Genck International
3 Somonauk Court, Park Forest, IL. 60466
Tel (708) 748-7200 Fax (708) 748-7208
genckintl@aol.com http://www.genckintl.com

Design/Scale-up
Size Distribution
Laboratory Investigations
Filtration
Troubleshooting
Purity
Caking
Drying
Particle Habit
Product Micro-Analysis
Polymorphism
Kinetics Studies
Industrial Seminars
51-56 Che 51-56.indd 54
12/26/07 5:57:49 Pm
Recruitment
SAUDI BASIC INDUSTRIES CORPORATION (SABIC), one of the top

ten petrochemical companies in the world wants to recruit professionals in
sales, marketing, investment planning and customers support for its Strategic
Business Unit dealing in Specialty Products in Riyadh, Saudi Arabia.
We are looking for candidates who have hands-on experience, creativity and
commitment and are looking for a bright future with a fast growing company.
Recruits are required in the following business areas:
Amines
MMA
Elastomers
Nylon
Ethoxylates
Caprolactam
Requirements
Education B.Sc. in a relevant engineering or financial field.
Experience Hands-on experience in the fields of marketing, sales, investment planning, and customer support of the specialty
products listed above.
Remuneration Competitive salary, free accommodation, transportation, flight
tickets to self and dependent family members, bonuses, full
medical coverage, and child education assistance.
Details Detailed job descriptions will be communicated upon evaluating the CV.
Candidates are invited
to apply through the
Triple EEE web site
+31 15 215 34 80
Tel:
+31 15 215 34 81
Fax:
info@eee.nl
Email:
Web site: www.eee.nl

51-56 Che 51-56.indd 55
55
12/27/07 5:17:54 Pm
Recruitment
Research Engineer
Conduct research and development
in membrane separation area with accountability for quality of experimental
data generated. Duties include: collecting parametric sensitivity data and system performance test runs; interacting
with principal investigators; reporting
to supervising R&D manager on all activities; and maintaining knowledge of
safety procedures and performing assigned duties in safe manner.
Requires Masters degree in Chem. Eng.
or related scientific discipline. Educ. or
exp. background must include: 1) chemical process simulation fundamentals; 2)
analytical techniques such as gas chromatography or high-performance liquid
chromatography. Exp. may be gained
concurrently. Employer will accept any
suitable combination of education,
training, or experience.
Membrane Technology and Research, Inc.
Attn: Human Resources

1360 Willow Rd., #103
Menlo Park, CA 94025
Fax to: 650-328-6580
Email to: careers@mtrinc.com
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HARTFORD TEXTILE COMPANY
We are HARTFORD TEXTILE COMPANY, we
need account representative that would work
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THE REQUIREMENT: Must be a computer
literate and be devoted. For more details
contact us at:
j.borough@hotmail.com
Classified
Tel: 212-621-4958
Fax: 212-621-4976
Faculty Positions in Materials Science & Engineering

Florida State University
Continuing Cluster Hire Initiative in
Growth, Processing and Characterization of Advanced Materials
In 2006, Florida State University announced a new faculty Cluster Hiring Initiative in the Growth, Processing and Characterization of Advanced Materials
(http://pathways.fsu.edu/faculty/gpcam/) as part of FSUs Pathways of Excellence Initiative (http://pathways.fsu.edu/). Inaugurated in the fall of 2005, the Pathways
program leverages the University's unique strengths with significant new investments in research and graduate education. This initiative is designed to hire faculty
who are national and international leaders in their respective fields, or are on a clear trajectory to be so, and who work effectively in an interdisciplinary team with
common intellectual goals.
The Growth, Processing and Characterization of Advanced Materials Cluster is interdisciplinary, blending many engineering disciplines with chemistry, physics and
computational sciences, with a goal of bridging the most basic science at the nanoscale with large scale applications of new technologies. This hiring initiative is part
of an emerging effort in Materials Science & Engineering at FSU, which includes new interdisciplinary graduate degree programs and a new Materials Research
Building, now under construction at the Florida State University Innovation Park site in close proximity to the College of Engineering (www.eng.fsu.edu), the National High Magnetic Field Laboratory (http://www.magnet.fsu.edu/), the Applied Superconductivity Center, the High Performance Materials Institute (http://www.
hpmi.net/) and the Center for Advanced Power Systems (http://www.caps.fsu.edu/).
The new hires will join two recent additions to the Cluster faculty, complementing present faculty at FSU who are active in a broad spectrum of materials research.
FSU is now accepting applications and nominations for up to four cluster positions:
1) A senior faculty position with expertise in the growth and characterization of oxide thin film materials,
2) A senior faculty position with expertise in the engineering of nano- and bio-devices, processing of nanocomposites, and advanced polymer and
composite engineering,
3) A junior faculty position to lead the physical sciences transmission electron microscopy initiative. FSU has committed resources for the purchase of
a forefront imaging and analytical resource that will be state of the art. Strong parallel support for the TEM facility comes from the Departments
of Chemistry, Physics, Mechanical, and Industrial & Manufacturing Engineering, and the Applied Superconductivity Center and National High
Magnetic Field Laboratory,
4) A junior faculty position with expertise in nano-manufacturing, advanced materials processing, multifunctional materials development, and modeling and/or computation in materials and manufacturing. The person is expected to bring skills and expertise complementary to existing High
Performance Materials Institute capabilities.
The Cluster faculty will be key members of the developing graduate materials programs at FSU and will have many opportunities to collaborate widely on campus
across disciplinary and departmental boundaries. Senior candidates must have clear international standing, an exceptional record of publishing and external funding and a demonstrated record of scientific leadership. Junior candidates must demonstrate progress towards similar achievements. All candidates should have the
appropriate terminal degree and the ability to teach at the graduate level in Materials Science & Engineering. The Cluster will favor candidates with strong communication skills and the ability and commitment to work in synergistic, interdisciplinary research programs. Appointees will be tenured or tenure-earning in an
academic department to be determined during the hiring process.
Nominations should include the name, address, telephone, and email contacts for the nominee along with a brief letter addressing the nominees qualifications. Applicants should submit a letter of interest which describes their areas of research and teaching, complete curriculum vitae, and the names and contact information
of at least three references. The review of applications will commence on February 15, 2008, and will remain open until all positions are filled.
Letters of nomination or application should be addressed to clusterhirechair@eng.fsu.edu. Only electronic applications will be accepted.
Florida State University is an Equal Opportunity/Access/Affirmative Action Employer

56
51-56 Che 51-56.indd 56
12/26/07 5:59:01 Pm
Advertisers Index
Advertiser
Phone number
Page number
Reader Service #
* A-T Controls Group
28D-6
513-247-5465 adlinks.che.com/7368-30
Axens

Beltran Technologies Inc
718-258-6887 adlinks.che.com/7368-10
Berndorf Band
GmbH & Co
28I-3
1-800-393-8450

Phone number
Page number
Reader Service #
Heinkel USA
28D-5
856-467-3399 adlinks.che.com/7368-28
Honeywell Process SECOND

Solutions
COVER
Hypercat Advanced
Catalyst Products
18
1-610-692-3490

28I-11
adlinks.che.com/7368-15 Commission

* Cashco Incorporated
20
785-472-4461 adlinks.che.com/7368-18
* Charles Ross
& Son Company
10
1-800-243-ROSS

Chemstations, Inc.
15
713-978-7700

Load Controls, Inc.

Micro Motion
Incorporated

FOURTH
COVER
Page number
Reader Service #
19
39-0731-231-1 adlinks.che.com/7368-40
Paratherm Corporation
* Paul Mueller Company
28
800-222-3611 adlinks.che.com/7368-05
1-800-MUELLER


28I-13
Prosim
33 (0) 5 62 88 24 30

56
FPC National
56
39 02 50 831 adlinks.che.com/7368-37
Donadon SDD

28I-10
Durr Systems,
Incorporated
28D-7
1-734-254-2314

Ekato Ruehr-Und
Mischtechnik
47
Emerson Process
Management
THIRD
COVER
* Endress + Hauser
49 7622 29 0 adlinks.che.com/7368-24
888-ENDRESS

Filtersense
28
1-978-927-4304

Finder Pompe Spa-Italy 28I-16
39-039-9982.1

Fisher-klosterman,
Incoroprated
28D-3
502-572-4000 adlinks.che.com/7368-25
Goulds Pumps,
Itt Industries
1-800-734-7867

International Section
* Additional information in
2006 Buyers Guide
24
39-02-5760-3913


Sri Consulting
29
TEMA
12
914-332-0040 adlinks.che.com/7368-13
The Western States

Machine Company
28D-6
513-863-4758

Westfalia Separator Ag
Consulting . . . . . . . . . . . . . . 54
Equipment, Used or
Surplus New for Sale. . . . 52-54
Recruitment. . . . . . . . . . . 55-56
Advertiser
Phone number
Page number
Reader Service #
Applied e-Simulators
Software
52
509-967-5730

Avery Filter Co.
53
201-666-9664

Bag Supply Company
53
800-722-5790

Bulkflow Technologies, Inc. 50
866-379-3500

CU Services LLC
50
847-439-2303

Custom Metalcraft, Inc.
52
EcReCon, Inc.
53
EquipNet Inc.
53
417-862-0707

856-299-4500

888-371-6555

Flowphase Engineering
Software
52
403-250-7522

Phone number
Page number
Reader Service #
212-302-1141

Genck International
54
708-748-7200

Graver Technologies
50
800-249-1990

H&P Equipment Co., Inc.
54
973-335-9770

Hartford Textile Co.
56
Heat Transfer Research, Inc. 52

979-690-5050

HFP Acoustical Consultants 54
888-789-9400

Hockmeyer
Equipment Corp.
53
252-338-4705

Indeck
54
847-541-8300

Intelligen, Inc.
51
KnightHawk Engineering
54
908-654-0088

281-282-9200

Membrane Technology
56
Advertiser
Phone number
Page number
Reader Service #
Midwesco Filter
Resources, Inc.
50
Minox/Elcan
54
Outotec Research Oy
52
Plast-O-Matic Valves, Inc.
50
Pulsair Systems
50
Rev Tech
54
Ross, Charles & Son Co.
53
Triple eee for Sabic
55
Wabash Power
Equipment Co.
54
Water Works
53
The Western States

Machine Co.
53
Xchanger, Inc.
52
800-336-7300

800-283-5226

+358-20-529 211

973-256-3000

800-582-7797

515-266-8225

800-243-7677

+31 15 215 34 80

847-541-5600

800-232-9334

513-863-4758

952-933-2559

57-58 CHE 1-08.indd 57
49-2522-77-0 adlinks.che.com/7368-11
Send Advertisements and Box replies to:

Helene Hicks, Chemical Engineering, 110 William St., 11th Floor, New York, NY 10038
Florida State University
28I-15
Saip Srl
Classified Index - January 2008 (212) 621-4958 Fax: (212) 621-4976
Computer Software . . . . . . 51-52
Desmet Ballestra Spa
28I-7
39-0521-274911

28I-12 * Samson Ag
Pieralisi Spa
Costacurta Spa Vico-Italy 28I-9
28D-8
Reader Service #
Munson Machinery
49 (0) 7623/969-0

Advertiser
832-242-1969 adlinks.che.com/7368-27
Page number
23 Robuschi & C.s.p.a.
Advertisers
Product Showcase. . . . . . . . 50
Daratech
Phone number
Muller GmbH
1-704-841-6000

39 02.66.20.20.66

Advertiser
See bottom of next page for advertising sales representatives' contact information
39-039-64214.1

26
Phone number
28D-4 Pompetravaini Spa
888-600-3247 adlinks.che.com/7368-26
Comber Drying & Filtration

Technology
28I-6
Conbraco Industries Inc.
Advertiser
1-877-466-3993
800-944-6644 adlinks.che.com/7368-17

adlinks.che.com/7368-01 Nuova Maip
17 Italian Trade
Bioengineering AG

Advertiser
57
12/27/07 2:41:39 PM
New Product Information

January 2008
JustFAXit! or go to www.che.com/adlinks
Fill out the form and circle or write in the number(s)
below, cut it out, and fax it to 800-571-7730.
Name
Go on the Web and fill out the

online reader service card.
Title
Company
Address
City
State/Province
Zip/Postal Code
Country\
Telephone
Fax
Email
FREEPRODUCT INFO
(please answer all the questions)
YOURINDUSTRY
01 Food &Beverages
02 Wood, Pulp &Paper
03 Inorganic Chemicals
04 Plastics, Synthetic Resins
05 Drugs &Cosmetics
06 Soaps &Detergents
07 Paints &Allied Products
08 Organic Chemicals
09 Agricultural Chemicals
10 Petroleum Refining,
Coal Products
11 Rubber &Misc. Plastics
12 Stone, Clay, Glass, Ceramics
13 Metallurgical &Metal Products
14 Engineering, Design &Construction Firms

15 Engineering/Environmental Services
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18 Other
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20 Corporate Management
21 Plant Operations incl. Maintenance
22 Engineering
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24 Safety &Environmental
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28 Less than 10 Employees
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YOURECOMMEND,
SPECIFY, PURCHASE
(please circle all that apply)
40 Drying Equipment
41 Filtration/Separation Equipment
42 Heat Transfer/Energy Conservation Equipment
43 Instrumentation & Control Systems
44 Mixing, Blending Equipment
45 Motors, Motor Controls
46 Piping, Tubing, Fittings
47
Pollution Control Equipment

&Systems
48 Pumps
49 Safety Equipment &Services
50 Size Reduction &Agglomeration
Equipment
51 Solids Handling Equipment
52 Tanks, Vessels, Reactors
53 Valves
54 Engineering Computers/Software/Peripherals
55 Water Treatment Chemicals
&Equipment
56 Hazardous Waste Management
Systems
57 Chemicals &Raw Materials
58 Materials of Construction
59 Compressors
16
31
46
61
76
91
106 121 136 151 166 181 196 211 226 241 256 271 286 301 316 331 346 361 376 391 406 421 436 451 466 481 496 511 526 541 556 571 586
17
32
47
62
77
92
107 122 137 152 167 182 197 212 227 242 257 272 287 302 317 332 347 362 377 392 407 422 437 452 467 482 497 512 527 542 557 572 587
18
33
48
63
78
93
108 123 138 153 168 183 198 213 228 243 258 273 288 303 318 333 348 363 378 393 408 423 438 453 468 483 498 513 528 543 558 573 588
19
34
49
64
79
94
109 124 139 154 169 184 199 214 229 244 259 274 289 304 319 334 349 364 379 394 409 424 439 454 469 484 499 514 529 544 559 574 589
20
35
50
65
80
95
110 125 140 155 170 185 200 215 230 245 260 275 290 305 320 335 350 365 380 395 410 425 440 455 470 485 500 515 530 545 560 575 590
21
36
51
66
81
96
111 126 141 156 171 186 201 216 231 246 261 276 291 306 321 336 351 366 381 396 411 426 441 456 471 486 501 516 531 546 561 576 591
22
37
52
67
82
97
112 127 142 157 172 187 202 217 232 247 262 277 292 307 322 337 352 367 382 397 412 427 442 457 472 487 502 517 532 547 562 577 592
23
38
53
68
83
98
113 128 143 158 173 188 203 218 233 248 263 278 293 308 323 338 353 368 383 398 413 428 443 458 473 488 503 518 533 548 563 578 593
24
39
54
69
84
99
114 129 144 159 174 189 204 219 234 249 264 279 294 309 324 339 354 369 384 399 414 429 444 459 474 489 504 519 534 549 564 579 594
10
25
40
55
70
85
100 115 130 145 160 175 190 205 220 235 250 265 280 295 310 325 340 355 370 385 400 415 430 445 460 475 490 505 520 535 550 565 580 595
11
26
41
56
71
86
101 116 131 146 161 176 191 206 221 236 251 266 281 296 311 326 341 356 371 386 401 416 431 446 461 476 491 506 521 536 551 566 581 596
12
27
42
57
72
87
102 117 132 147 162 177 192 207 222 237 252 267 282 297 312 327 342 357 372 387 402 417 432 447 462 477 492 507 522 537 552 567 582 597
13
28
43
58
73
88
103 118 133 148 163 178 193 208 223 238 253 268 283 298 313 328 343 358 373 388 403 418 433 448 463 478 493 508 523 538 553 568 583 598
14
29
44
59
74
89
104 119 134 149 164 179 194 209 224 239 254 269 284 299 314 329 344 359 374 389 404 419 434 449 464 479 494 509 524 539 554 569 584 599
15
30
45
60
75
90
105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 435 450 465 480 495 510 525 540 555 570 585 600
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Product Showcase, Literature Reviews, Chemical Engineering
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Alaska, Hawaii, Idaho, Mississippi,
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57-58 CHE 1-08.indd 58
12/27/07 2:42:10 PM
Economic Indicators
Business News
Plant Watch
A new plant for crude-oil processing
to be built in Italy
December 10, 2007 ABB has won a
contract worth more than $86 million from
Eni SpA to design and construct a new oil
processing plant in an onshore oilfield in
Italy.The plant, scheduled for completion
in 2010, will process almost 7,000 bbl/d of
crude oil and 6.7-million ft3/d of gas. It is part
of the larger onshore oilfield development
project, which includes a sulfur treatment
plant, wellhead facilities and a power
generation plant.
A complex is planned in North America
for clean transportation fuels
December 5, 2007 Newfoundland &
Labrador Refining Corp. (NLRC) has selected
UOP LLC, a Honeywell company, to supply
technology, basic engineering services and
equipment for a fuel refinery to be built in the
Placentia Bay area of Newfoundland and
Labrador, Canada. Startup of the complex is
scheduled for 2011.The facility is projected
to process 300,000 bbl/d of Middle Eastern
crudes for the production of transportation
fuels to support demand in North America
and Europe.The NLRC facility will be the first
new refinery constructed in North America
since 1984.
LP Oxo Technology is chosen for a new
facility in Sichuan Provence, China
November 28, 2007 PetroChina Sichuan
Petrochemical Co. has chosen LP Oxo
Technology for its new facility in Chengdu,
Sichuan Province, China.The Sichuan plant
will include the largest custom-designed
single-line low-pressure hydroformylation
unit in the world, with a capacity of 338,000
m.t./yr of normal- and iso-butyraldehydes.
This train will supply two alcohol production
lines, with the first producing 81,800 m.t./yr
of 2-ethylhexanol and the second, 211,900
m.t./yr of normal-butanol and 30,800
m.t./yr of iso-butanol. Startup is planned
for September 2010.This facility is part of a
grassroots petrochemical complex that
PetroChina centered on an 800,000-m.t./yr
ethylene plant.
Portuguese refiner becomes second to
license biofuel technology
November 28, 2007 Portugals largest
refiner, Galp Energia, will use the UOP/Eni
Ecofining technology to produce diesel
fuel from vegetable oils in a new process

unit.The Galp Energia facility, to be located
in Sines, Portugal, will process 6,500 bbl/d
of vegetable oils to supply European
refineries with a high-cetane green diesel
fuel.The Ecofining process uses catalytic
hydroprocessing technology to convert
vegetable oils to a green diesel fuel.The
product features a high cetane value (the
measure of the combustion quality of
diesel) of approximately 80 as compared
to diesel found at the pump today, which
ranges from 40 to 60 cetane (for a related
story see CE, July 2007, p. 83 and for more on
the process, see CE, May 2007, p.18).
BASF increases capacity for higher oxo
alcohols and plasticizers
November 27, 2007 BASF is to raise
production capacity in Ludwigshafen for
higher oxo alcohols by 80,000 m.t./yr to
a total of 390,000 m.t./yr.The additional
capacity is earmarked mainly for the
manufacture of plasticizers, whose
production capacity BASF also plans
to raise by 40,000 to 300,000 m.t./yr.The
increased plasticizer production capacity
is scheduled to be in place by the 2nd Q of
2008.The additional production capacities
for oxo alcohols are to be built up stepwise
through the end of the 1st Q of 2009.
Brazilian complex chooses
Axens technologies
November 19, 2007 Petrobas will license
Axens ParamaX and other technologies
for its Rio de Janeiro Petrochemical
Complex (Comperj) located in Itaborai,
Brazil.The complex represents one of the
largest investments in the world, totaling
an estimated $8.5 billion. Due to come
onstream in 2012 and to be fully operational
in 2013, Comperj will have a processing
capacity of 150,000 bbl/d of Brazilian heavy
oil.The first phase of the project will produce
about 1.5-million ton/yr of high-purity
aromatics components: 780,000 ton/yr of
para-xylene and 690,000 ton/yr of benzene.
Site selected in Louisiana for new
renewable fuels plant
November 15, 2007 Geismar, La. has
been selected as the site for Dynamic
Fuels new plant to produce renewable
diesel and jet fuels.The $135-million facility
will have a capacity of 5,000 bbl/d and is
scheduled for completion in 2010. Dynamic
Fuels, LLC is a 50/50 venture between
Syntroleum Corp. and Tyson Foods, Inc. to

construct and operate multiple renewable
synthetic fuel facilities.
Mergers and
Acquisitions
Rockwell acquires Pavilion Technologies
and expands software portfolio
December 6, 2007 Rockwell Automation
has entered into a definitive agreement to
buy Pavilion Technologies, Inc., a privately
held company involved in advanced
process control, production optimization
and environmental compliance solutions
for process and hybrid industries.The
Pavilion Technologies management
team and employees will become part
of Rockwell Automations Architecture &
Software segment.Terms of the transaction
were not disclosed.
Basell to acquire Solvay
Engineered Polymers, Inc.
November 29, 2007 Basell, a leader in
advanced polyolefins, has signed a definitive
agreement with Solvay by which Basell will
acquire Solvay Engineered Polymers, Inc.,
a supplier of polypropylene compounds in
North America.The transaction is subject
to relevant regulatory approvals and is
expected to close in early 2008.
A joint venture is formed for an ongoing
biodiesel-expansion project in France
November 26, 2007 Ineos Enterprises is
moving forward with its project to more than
double biodiesel capacity at its Baleycourt
site in Verdun, France. A new joint venture
(JV), to be known as Ineos Champlor has
been created by INEOS Enterprises, farming
cooperative group Sicla, and oilseed
crushing group C.Thywissen.The JV will
invest more than 70 million in a new oilseed
crushing unit and vegetable-oil refining
plant at the site.The new biodiesel facility
will allow around 400,000 m.t. of locally
produced rapeseed to be transformed into
oil and then biodiesel.
The Linde Group sells BOC Edwards
Pharmaceutical business
November 23, 2007 The Linde Group has
sold the BOC Edwards Pharmaceutical
Systems business to the Italian company
IMA (Industria Macchine Automatiche) at
n
an enterprise value of 36 million.

Dorothy Lozowski
For additional news as it develops, please visitwww.che.com

January 2008; VOL. 115; NO. 1
Chemical Engineering copyright @ 2008 (ISSN 0009-2460) is published monthly, with an additional issue in October, by Access Intelligence, LLC, 4 Choke Cherry Road,
2nd Floor, Rockville, MD, 20850. Chemical Engineering Executive, Editorial, Advertising and Publication Offices: 110 William Street, 11th Floor, New York, NY 10038; Phone: 212621-4674, Fax: 212-621-4694. Subscription rates: $59.00 U.S. and U.S. possessions, Canada, Mexico; $179 International. $20.00 Back issue & Single copy sales. Periodicals
postage paid at Rockville, MD and additional mailing offices. Postmaster: Send address changes to Chemical Engineering, Fulfillment Manager, P.O. Box 3588, Northbrook,
IL 60065-3588. Phone: 847-564-9290, Fax: 847-564-9453, email: clientservices@che.com. Change of address, two to eight week notice requested. For information regarding
article reprints, please contact Client Services, clientservices@accessintel.com; Tel: 800-777-5006 (toll-free within the US) or 301-354-2101; fax: 301-309-3847. Contents may
not be reproduced in any form without written permission. Publications Mail Product Sales Agreement No. 40558009. Return undeliverable Canadian Addresses to:
P.O. Box 1632, Windsor, ON N9A7C9.
For more Economic Indicators, See Next Page
59-60 CHE 1-08.indd 59
59
12/27/07 1:32:12 PM
Economic Indicators
2006
2007
DOWNLOAD THE CEPCI TWO WEEKS SOONER AT WWW.CHE.COM/PCI
CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI)

(1957-59 = 100)
Oct.07
Prelim.
527.1
626.2
593.2
595.0
740.2
422.1
843.2
437.2
660.8
318.6
476.8
355.0
CE INDEX
Equipment
Heat exchangers & tanks
Process machinery
Pipe, valves & fittings
Process instruments
Pumps & compressors
Electrical equipment
Structural supports & misc
Construction labor
Buildings
Engineering & supervision
Sep.07
Final
528.2
627.2
595.1
599.6
739.6
422.8
836.2
435.3
663.5
320.1
478.4
355.9
540
Oct.06
Final
515.5
610.4
571.5
562.8
740.5
439.0
794.2
419.2
646.0
314.0
474.6
351.9
Annual Index:
1999 = 390.6
525
2000 = 394.1
2001 = 394.3
510
2002 = 395.6
2003 = 402.0
495
2004 = 444.2
2005 = 468.2
480
2006 = 499.6
465
* Starting with the April 2007 Final numbers, several of the data series for labor and compressors have been
converted to accommodate series IDs that were discontinued by the U.S. Bureau of Labor Statistics
F M A M J
A S O N D
CURRENT BUSINESS INDICATORS
LATEST
CPI output index (2000 = 100)

CPI value of output, $ billions
CPI operating rate, %
Construction cost index (1967 = 100)
Producer prices, industrial chemicals (1982 = 100)
Industrial Production in Manufacturing (2002=100)*
Hourly earnings index, chemical & allied products (1992 = 100)
Productivity index, chemicals & allied products (1992 = 100)
Nov.07
Oct. 07
Nov. 07
= 108.8
= 1,697.6
= 82.0
Oct. 07
Sep. 07
Oct. 07
=
=
=
108.3
1,665.3
81.7
Sep. 07
Aug. 07
Sep. 07
= 109.1
= 1,614.8
= 82.4
Nov. 06
Oct. 06
Nov. 06
= 106.0
= 1,549.2
=
80.7
Dec. 07
Nov. 07
Nov. 07
Nov. 07
Nov. 07
=
=
=
=
=
Nov. 07
Oct. 07
Oct. 07
Oct. 07
Oct. 07
=
=
=
=
=
753.3
229.8
115.3
141.3
132.8
Oct. 07
Sep. 07
Oct. 07
Sep. 07
Sep. 07
=
=
=
=
=
Dec. 06
Nov. 06
Nov. 06
Nov. 06
Nov. 06
=
=
=
=
=
111
CPI OUTPUT INDEX (2000 = 100)
1760
PREVIOUS
753.1
245.8
115.8
143.0
132.1
CPI OUTPUT VALUE ($ Billions)
85
108
1680
83
105
1600
81
102
1520
79
99
1440
77
96
J A S O N D
749.0
227.7
116.1
142.3
131.9
734.3
208.3
113.2
143.1
131.6
CPI OPERATING RATE (%)
75
1360
J F M A M J
YEAR AGO
J F M A M J
J A S O N D
J F M A M J
J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
Current business indicators provided by DRI-WEFA, Lexington, Mass.
THE ONLINE CEPCI
MARSHALL & SWIFT EQUIPMENT COST INDEX

(1926 = 100)
M & S INDEX
Process industries, average
Cement
Chemicals
Clay products
Glass
Paint
Paper
Petroleum products
Rubber
Related industries
Electrical power
Mining, milling
Refrigeration
Steam power
4th Q
2007
3rd Q
2007
2nd Q
2007
1st Q
2007
4th Q
2006
1,399.2
1,452.3
1,435.3
1,427.9
1,415.0
1,348.8
1,457.1
1,369.2
1,543.7
1,500.1
1,393.0
1,445.6
1,427.5
1,421.0
1,408.8
1,341.8
1,451.2
1,364.0
1,536.2
1,494.8
1,383.6
1,433.5
1,417.5
1,408.8
1,400.4
1,331.3
1,440.2
1,354.0
1,521.0
1,486.7
1,362.7
1,410.0
1,398.8
1,384.9
1,378.1
1,309.5
1,414.2
1,331.6
1,497.9
1,463.1
1,353.8
1,399.2
1,385.8
1,374.1
1,367.6
1,299.5
1,404.6
1,324.2
1,486.3
1,449.4
1,374.9
1,460.8
1,698.8
1,416.4
1,359.0
1,453.2
1,691.7
1,407.4
1,340.7
1,442.7
1,679.3
1,394.2
1,319.5
1,427.7
1,648.2
1,369.1
1,310.1
1,413.5
1,638.5
1,359.8
Annual Index:
2000 = 1,089.0
2001 = 1,093.9
2002 = 1,104.2
2003 = 1,123.6
2004 = 1,178.5
2005 = 1,244.5
2006 = 1,302.3
2007 = 1,373.3
60$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
CEs Online CEPCI provides access to the entire historical CEPCI

database (top). And, instead of
waiting more than two weeks for
the print or online version of the
magazine to arrive, subscribers
to the Online CEPCI can download new data as soon as it is
calculated. Visit www.che.com/
pci to subscribe to the following:
1405
1390
1375
1360
1345
1330
1315
1300
1285
1270
1255
1240
1225
1st 2nd 3rd 4th

Quarter
Electronic notification of
monthly updates
All annual data archives
(1947 to present) and monthly
data archives (1970 to present)
Option to download data in
Excel format
A selection of helpful
cost-estimation articles
O
12/13/07 3:16:31 PM
12/13/07 3:14:35 PM

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