Ing. Qca.

November
2007
Steam Trap
Management
Page 40
www.che.com
Making the right connections

Page 34
Dust
Control
Managing
Global Supply
Chains
Liquid Density
of the Elements
Programmable
Logic Controllers
Cover 1 CHE 11-07.indd 1
Focus on
Pipes and Fittings
Facts at Your
Fingertips:
Pump Selection
and Specification
Managing
Material Safety
Data Sheets
10/29/07 5:04:49 PM
HPS sRe_Chem Eng Ad 11-07
10/10/07
4:17 PM
Page 1
HPS sRe_Chem Eng Ad 11-07Pub: Chemical Engineering
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1 CHE 11-07.indd 1
10/15/07 12:14:16 PM
2 CHE 11-07.indd 2
10/15/07 12:23:51 PM
November 2007
In This Issue
Volume 114, no. 12

commentary
5 Editors Page
Here's a note on
the wireless
standards debate
www.che.com
30 CE Community
Cover story
Chemical Engineering has introduced its

new website at
www.che.com
34 C
over Story Going Wireless Using this technology
to optimize overall operations offers long-term benefits
for the bottom line
NEWS
departments
13 Chementator This membrane could reduce the carbon
Letters . . . . . . . . . . . . 6
footprint for combustion power plants; Plasma gasification process will recycle chlorine wastes and produce
syngas; Slash downstream processing costs for producing
biologicals with this new chromatography technology;
Japanese water-treatment filter enters U.S. market boasting no need to replace granular filter media ever; A fast
way to measure phase fractions in multiphase flow; This
catalyst may open the door to green copolymer of CO2;
A second major plant for a new PO process; and more
20 Newsfront Its a Small World managing

the chemical supply chain in a global economy requires visibility and collaboration
25 Newsfront Keep Control of Your Dust Energy saving, emission regulations, explosion
protection and finer filters combine to drive
the market in particulates removal
Engineering
29 Facts At Your Fingertips Pump Selection

and Specification This one-page guide will
help an engineer in determining the best
pump for a specific application
40 Feature Report The Importance of Intensive Steam Trap Management Payback is

rapid, energy and maintenance savings are
attractive, and the uptime insurance is incalculable in value
44 Engineering Practice Liquid Density

of the Elements A comprehensive
tabulation for all the important elements
from Ag to Zr
47 Engineering Practice PLC Maintenance

Management PLCs are critical to the success of CPI processes. These requirements
for proper PLC management go a long way
toward reducing downtime and unnecessary costs
53 Environmental Manager Managing

Material Safety Data Sheets in the Workplace While regulatory agencies outline
requirements for communicating chemical
hazards, the format of compliance is up to
the employer. Software tools can be helpful
aids in meeting these requirements
Bookshelf. . . . . . . 8,10
Whos Who. . . . . . . . 32
Reader
Service page. . . . . . . 70
Economic
Indicators. . . . . . 71, 72
equipment & services
advertisers
32D-1 New Products & Services (Domes-
Product
Showcase. . . . . . . . . . . 59
tic Edition) Moderate sample temperatures with this unit; Clean filters without
downtime with this duplex basket strainer;
Detect leaks from up to 30 feet away; Stop
spills at the first drop; Dry a variety of materials with this unit; Convert plain hubs into
integral clamps; and more
32I-1 New Products & Services

(International Edition) Your view is not
obstructed by this mask; Determine water
content with this automatic titrator; When
space is limited, consider this centrifugal
pump; Angle-seat globe valves now come
with flange connections; Easy to install lining protects against spills in tank rooms;
Convert thermocouple data into 4-20 mA
signals with this module; and more
50 Focus Pipes and Fit tings Make a leak-free
seal, even for irregular
flanges; Replace copper plumbing lines with
a plastic that looks
golden; Dip pipes that
require less space and
reduce installation
costs; Many different
applications are served
by this nylon tubing;
This tubing and related
products have passed the test; Just one
gasket type is suitable for steel, plastic
or glass flanges; For high-temperature
plumbing, consider these fittings
Classified
Advertising. . . . . 6065
Advertiser Index . . . . 69
coming
in december
Look for: Feature
Reports on Practical
Green Engineering; and
Valve Position Monitoring: Advancements
Improve Performance
and Lower Costs; Engineering Practice
articles on Accurate
Wetted Surface Areas
for Partially Filled Vessels; and Use Your
Own Models in Process
Simulation; A Solids
Processing article on
Weighing; A Focus on
Gas Detection; News
articles on the Kirkpatrick Awards and Heat
Transfer Equipment; a
Chem Show Review;
Facts at Your Fingertips on Seals and Sealing Systems; and more
Cover source:
Honeywell
Chemical Engineering www.che.com November 2007
3 CHE 11-07.indd 3
10/29/07 5:18:51 PM
Isn't it a
safe choice?
SIL
er
Saf
e
nd
Integrity Le
vel
ty
ress + H au
High temperature level

measurement
Discover a new degree of safety
Who turned up the heat?
New radar, guided radar (TDR) and point level instruments are
specically engineered to withstand high temperatures up to
750 F, high pressures up to 5,800 psi and aggressive media.
The right instrument for the job
Endress+Hauser will help you nd the best devices for
your requirements. Guided radar offers reliable measurement
that is not inuenced by density changes. Free space radar
Micropilot M offers non-contact level measurement.
The Liquiphant is a self-monitoring, trouble-free solution
for all liquid level switch applications.
Your safe choice
Endress+Hauser offers the widest range of systems for level
measurement or point level detection in solids or liquids.
All three instruments shown here are rated for use in safety
instrumented systems.
www.us.endress.com
For application and selection assistance,
in the U.S. call 888-ENDRESS
For total support of your installed base
24 hours a day, in the U.S. call 800-642-8737
4 CHE 11-07.indd 4
10/15/07 12:04:03 PM
Winner of Eight Jesse H. Neal

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Editors Page
Cooperation looks promising

for wireless standards
tandardization is a challenging but necessary path in the chemical

process industries (CPI), whether it pertains to pumps, process equipment or one of the most-recent focuses and topic of this months Cover
Story (p. 34), wireless instrumentation and control. Without standardization, a lack of interoperability can nearly defeat the noble purposes that
untethered instrumentation and control is designed to provide. Quite often,
though, the process of standardization, itself, introduces multiplicities that
in themselves must be straightened out.
In hopes of laying a smooth foundation for wireless standards from the
beginning, the powers that be in this case, namely the ISA100 Wireless
Systems for Automation Standards committee and members of the HART
Communication Foundation (HCF; www.hartcomm.org), are making a
valiant effort toward integrating the recently released WirelessHART
standard into the yet-to-be released ISA100. From a manufacturers
standpoint, nobody wants to build three or four different flavors of wireless, says Ron Helson, HCF executive director. There is no benefit to the
user, and it just increases the cost.
Given the scope of each standard and timing of the cooperation, this integration approach just might work. It isnt too far off from how HCF has
cooperated with Foundation Fieldbus, Profibus via electronic device description language (EDDL) initiatives, notes Helson. But it is different in
that the discussion is taking place at a much earlier time in the process.
If you look at ISA100, it has a much broader scope than WirelessHART,
points out Helson. WirelessHART has defined the way messages are communicated between the wireless field devices in process applications and
the gateway. ISA100, by contrast, could go way on up into the higher control and enterprise platform. Furthermore, ISA100 is defining standards
for wireless communication in factory automation and discrete devices,
which are significantly different than those in process devices.
The agreed upon approach will attempt to accommodate the HART7 wireless protocol in Release 1 of the ISA100.11a standard through a
dual-gateway architecture, followed by a potentially more integrated
approach in Release 2 of the ISA standard. The ISA100-WirelessHART
Analysis Team is evaluating how the WirelessHART protocol within
HART 7 can be incorporated into the ISA100.11a standard while remaining consistent with the objectives of the ISA100 family of standards,
said ISA100 co-chair Pat Schweitzer of Exxon Mobil during a meeting
between the two organizations at ISA 2007 last month in Houston. The
most important part of that evaluation is the obligation to continue our
commitment to the end user, and were confident that our final decisions
will accomplish that goal.
As Jeff Becker, director of global wireless business for Honeywell Process Solutions and author of this months Cover Story, adds, wireless
performance for the end user is indeed what ultimately
matters most in this context. End users only have one
introduction to wireless technology. If the technology
doesnt work well and easily the first time, the second
time will be much farther down the road.
Beyond this common goal, there is agreement on
at least one more fact that appears to be consistent
among all parties: As HCF's Helson says, The good
thing is, were talking.
Rebekkah Marshall
5 CHE 11-07.indd 5
10/29/07 5:06:57 PM
Letters
Mining company offers $10 million
for innovation to unlock the silver
Barrick Gold Corp. (Toronto) has challenged scientists

worldwide, offering $10 million to anyone who can unlock the silver from the ore at its Veladero gold mine
in Argentina.
Barricks Unlock the Value program invites scientists, engineers and other inventors to solve a scientific
conundrum. Geologists have determined there are 180million ounces of silver contained in gold reserves in
the ore at the Veladero mine in Argentina. Because the
silver particles are encapsulated in silica, current processing methods are recovering only 6.7% of the silver.
The Unlock the Value program invites proposals for an
economically viable way to significantly increase silver
recovery from this type of ore.
For proposals judged to have merit, Barrick will fund
research and development. For a technology that is successfully implemented at Veladero, the company will
pay a performance bonus of $10 million.
This opportunity will appeal to chemists, metallurgists, physicists, engineers, or any inventor with a
new concept for improving silver recovery, says Greg
Wilkins, president and CEO. Experience in mining
is not required because we are looking for innovation and new approaches. The $10-million award is a
substantial incentive to spur creative thinking but,
beyond that, Barrick will fund research and development for proposals that have merit. Scientists sometimes have difficulty finding funding to take their
good ideas to the next level, so we believe this will be
a welcome aspect of the program.
Interested researchers can register and submit
proposals through a special website at www.unlockthevalue.com. Preliminary proposals must be submitted by January 21, 2008, to be considered for the
next stage of proposal development. Proposals will
be assessed by a team of experts and evaluated on
their technical viability and ability to be safely implemented at Veladero. Those judged to have merit will
be invited to submit a detailed proposal. If successful,
they will go on to further phases of development, testing and commercial evaluation.
Barricks Veladero mine is located in San Juan Province, Argentina, about 320 kilometers northwest of the
city of San Juan in the highly prospective Frontera
District. It is located at elevations of between 4,000 and
4,850 meters above sea level, and comprises two open
pits Filo Federico to the north and Amable to the
south. Barrick invested about $540 million to construct
the mine, creating 4,000 jobs during the construction
phase and 800 full time jobs during operation. The mine
opened in October, 2005. In 2006, its first full year of
production, Veladero produced 511,000 ounces of gold.
Barricks vision is to be the worlds best gold company by finding, acquiring, developing and producing
quality reserves in a safe, profitable and socially responsible manner.
n

6 CHE 11-07.indd 6
10/26/07 5:50:50 PM
34453-1GR Trade Ad C-410
9/6/07
10:01 AM
Page 1
Gorman-Rupp has the right pump for the job. Whether youre pumping clear liquids,
highly viscous liquids at high pressures, chemical process or mild slurry, Gorman-Rupp
pumps are designed to handle tough abrasive and corrosive chemicals where other
pumps fail. Whether its a standard centrifugal, a self-primer, gear, submersible or
diaphragm pump, Gorman-Rupp meets your needs. Look to Gorman-Rupp for pumps
that solve all types of chemical handling problems.
Ask your local Gorman-Rupp distributor which pump is best for your job.
The Gorman-Rupp Company P.O. Box 1217 Mansfield, Ohio 44901-1217 n USA
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C-410
Copyright, The Gorman-Rupp Company, 2007
Gorman-Rupp Mansfield Division is an ISO 9001 Registered Company
7 CHE 11-07.indd 7
10/15/07 12:10:07 PM
Bookshelf
Transport Phenomena in Multiphase
Systems. By Amir Faghri and Yuwen
Zhang. Elsevier, 11830 Westline Industrial
Drive, St. Louis, MO 63146. Web: wiley.
com. 2006. 1030 pages, $99.95.
Reviewed by Clarence A. Miller, Department of Chemical and Biomolecular Engineering, Rice University, Houston, Tex.
From Concept to Completion,

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ritten at a level suitable for a textbook in a

graduate engineering course or for researchers in
heat transfer with simultaneous phase transformation, this book presents a comprehensive treatment of
a variety of phenomena. It includes recent analyses of applications of current interest. The derivations and analyses are accompanied by numerous examples worked out
in the text and by several pages of problems at the end of
each of the eleven chapters.
In approximately 100 pages, the first chapter provides
a summary of basic concepts and equations ranging from
kinetic theory and intermolecular forces to nanoscale phenomena to transport phenomena including thermal and
multicomponent diffusion. Vectors and tensors are used as
appropriate. This part of the chapter is rather condensed
and best suited for those already having a background in
transport phenomena. The last third of the chapter is a
nice overview of applications of heat transport with phase
transformation, most of which are analyzed in detail in
subsequent chapters.
Chapters 2 and 3 discuss thermodynamics needed for the
topics of later chapters, and development of the basic conservation equations and boundary conditions. Included is
the differential entropy balance equation with expressions
for the entropy flux and rate of entropy generation.
Chapter 4 covers averaging of the governing equations
for flow and transport in porous media with both a single
and with multiple fluid phases present. A few pages
provide an introduction to the Lattice-Boltzmann model.
Chapter 5 deals with interfacial phenomena: surface tension, contact angles, interfacial conservation equations
and also less familiar concepts, such as disjoining pressure in thin films.
The remaining chapters are the heart of the book and
consist of discussion and analysis of melting, solidification,
sublimation, condensation, evaporation, boiling and twophase flow with heat transfer. Many interesting applications are discussed, such as ablation, heat pipes, phase
transformation in microchannels, and bubble dynamics
in boiling. The analyses are thorough and based on analytical or numerical solutions of the governing equations
and boundary conditions. The book includes sections on
numerical methods that are useful in dealing with phase
changes with moving boundaries and free surfaces, although a background in numerical methods comparable to
that of an advanced undergraduate engineering student is
assumed. I used or adapted a few of their examples in my
graduate chemical engineering transport course this year.
Even a book of 1,000 pages cannot cover everything. As
8-10 CHE 11-07.indd 8
10/25/07 7:27:14 PM
VEBE_0707402_FishUS_200x273_2.qxd
5/10/07
13:19
Page 1
LPR -
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CHEMICAL ENGINEERING US fish 200x273 mm PP Q Delivery 05/10/2007 -Issue 05/11/2007

9 CHE 11-07.indd 9
10/15/07 12:28:41 PM
Bookshelf
the authors are primarily interested in applications of heat
transfer, chemical engineers will find little on phase change
involving nonideal, multicomponent liquid solutions or
gas mixtures at high pressure. Chemical reactions are discussed mainly in the section on chemical vapor deposition.
Mass transfer appears chiefly in situations where heat
transfer is also taking place during a phase change. Effects
of surfactants at interfaces are not considered.
In summary, the authors have achieved their objective of providing a different type of book on transport. It
takes a fundamental approach to present an authoritative
treatment of many interesting phenomena and important
applications involving phase transformation. I highly recommend the book for students and researchers interested
in or working in this area.
Separation Process Engineering. Second Edition. By Phillip C. Wankat. Prentice Hall, 1 Lake St., Upper Saddle River,
NJ 07458. Web: prenhall.com. 2007. 704
pages. $127.00.
Process Chemistry of Lubricant
Base Stocks. By Thomas R. Lynch.
CRC Press, 6000 Broken Sound Parkway, NW, Suite 300,
Boca Raton, FL 33487. Web: crcpress.

com. 2007. 392 pages. $139.95.
A Real-Time Approach to Process
Control. Second edition. By William Y.
Svrcek, Donald P. Mahoney and Brent R.
Young. Wiley, 111 River St., Hoboken, NJ.
Web: wiley.com. 2006. 344 pages. $190.00.
Rheology and Processing of Polymeric Materials,
Volume 1: Polymer Rheology. By By Chang Dae Han.
Oxford University Press, 198 Madison Ave., New York, NY
10016. Web: oup.com. 2007. 1,333 pages. $174.80.
Advanced Transport Phenomena.
By L. Gary Leal. Cambridge University
Press, 32 Ave. of the Americas, New
York, NY 10013-2473. Web: cambridge.
org. 2007. 932 pages. $135.00
Chemical Reactor Design and Control. By William L. Luyben. Wiley, 111
River St., Hoboken, NJ. Web: wiley.com.
2007. 417 pages. $115.00.
n
Kate Torzewski
10
8-10 CHE 11-07.indd 10
10/29/07 3:06:48 PM
EHRENSTRHLE BBDO
One single unit instead

of seven Shell & Tubes
DSM Special Products produces benzoic acids and derivatives. A critical

element in the process is the ammonia cooler. Until recently, DSM was using
seven Shell & Tube heat exchangers in series for this application. However,
due to severe corrosion problems there was a sudden need for a new cooler.
A quick feasibility study clearly showed that one single Alfa Laval Compabloc
was an extremely competitive solution. Delivery time was short. And thanks
to the lower capital cost it was possible to select a corrosion-resistant plate
material without exceeding the budget. A matter of basic arithmetic!
The Magic Box. Compabloc is probably the most compact and efficient
heavy-duty heat exchanger in the world. Its remarkable design adds a new
Arnold Blonk. Process Engineer
DSM special products plant,
Rotterdam, Holland
dimension to both cooling/heating and condensation/reboiling. It has extremely

high thermal efficiency ... withstands aggressive media ... operates at high
pressures and temperatures ... and requires a minimum of space. And it works
magic on your wallet.
www.alfalaval.com
11 CHE 11-07.indd 11
10/15/07 11:57:56 AM
RO-2111C Tom Di -Industrial Ad for Chemical Eng. size: 7.875 x 10.75 (Bleed: 8.125 x 11.5) 4-c date: 10/08/07 (SCD#07ROSS026)
In the auto
industry, no one
drives faster
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Uniseal is known throughout
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With fast-moving R&D,
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see why this company has
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To keep production in the
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Wed like to help you succeed, too.
Call 1-800-243-ROSS.
Or visit www.mixers.com.
Tom DiGiannurio,
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Ross Employee Owner
12 CHE 11-07.indd 12
10/15/07 12:00:12 PM
Edited by Gerald Ondrey
November 2007
'FFETJEF
This membrane could reduce the carbon

footprint for combustion power plants
ithin five years, four large power plants

in Europe will be outfitted for testing at the pilot scale with energy-efficient
CO2-filtering membranes that are being
developed at the Norwegian University of
Science and Technology (NTNU; Trondheim; edlinks.che.com/6901-531). Professor
May-Britt Hgg, head of the membrane research group (MEMFO) at NTNUs chemical engineering department, says that the
membrane is the first cost-effective means
of removing CO2 from flue gas. Hgg also
says that the membrane can easily retrieve
85% of the CO2 at 90% purity.
Conventionally, carbon capture from flue
gas has required large absorption towers
where gas is bubbled through a hazardous
amine solution, which must then be transported to an energy-intensive desorption
tower for CO2 removal. Among the proposed
alternatives, supported liquid membranes
have tended to degrade quickly, due to entrainment of CO2-carrier liquids in the gas
flow. MEMFOs membrane resolves these
issues by using a comparatively immobile
polyvinylamine nanoplastic as a fixed-site
carrier, with NH4F crosslinked in its polymer structure for improved anion exchange.
When saturated with water vapor from the
$)
$0
$0
/)
flue gas, the amine and
fluoride ions will indi0OMZCZ
EJGGVTJPO
)0
vidually complex with
1PMZNFS
CO2 as bicarbonate.
MBZFS
3FWFSTJCMF
Frequent regeneration
SFBDUJPO
DPBUFE
POQPSPVT
of the membrane is not
TVQQPSU
needed as the HCO3

)$0 /)
anion reemerges as
CO2 after it is shuttled
)0
$0
through (diagram).
The membrane has
been tested at laboratory scale for five years
1PSPVTTVQQPSU
using a simulated flue
gas of heated nitrogen,
$0
$)
methane, carbon dioxide
1FSNFBUFTJEF
and water vapor. We are
Extracting HMs
about to build a small pilot for a small gas
The latest issues of the J. of
stream (about 0.15 Nm3/h) focusing much
Separation Sci. and the J. of
on durability of the membrane over time
Colloid Interface Sci. report on
when exposed to real flue gas, says Hgg.
a new material, nanostructured
silica, which can be functionalIf tests go well, we will go for a larger pilot
ized to extract heavy metals
in about three years.
(HMs), such as mercury, lead,
MEMFO was recently awarded 1 milcadmium and zinc, from wastelion for its participation in Nanostrucwater. The material, being detured Membranes against Global Warmveloped at the Universidad Rey
ing, a 13-million consortium project
Juan Carlos (Madrid, Spain;
with 26 European institutions and indusedlinks.che.com/6901-539),
trial partners.
mimics the reaction that bonds
Plasma gasification process will

recycle chlorine wastes and produce syngas
plasma-based waste-treatment process

will be installed in Dow Corning Corp.s
silicon-products-manufacturing plant in
Midland, Mich., where it will recycle chemical wastes, help lower the sites consumption
of natural gas by 400-billion Btu/yr and help
reduce the plants total emissions by 75%.
The installation will mark the first use of the
technology in a chemical process plant, says
Jeffrey Surma, CEO of Integrated Environmental Technologies, LLC (IET, Richland,
Wash.; edlinks.che.com/6901-532), which
owns the technology. In its initial installations, the plasma-enhanced melter (PEM)
is being used to destroy medical wastes and
chemical wastes, he says.
The PEM is a vessel that contains a molten glass bath, above which are graphite
electrodes that generate a plasma arc. In
Note: For more information, circle the 3-digit number
on p. 70, or use the website designation.
13-18 CHE 11-07.indd 13
$BSSJFSTGJYFEPO
QPMZNFSCBDLCPOF
the Dow Corning plant, waste chlorosilanes

(from intermediate products) will be fed into
the plasma arc. Organics in the waste will
be gasified to a hydrogen-rich syngas and
removed, along with hydrogen chloride. The
HCl will be scrubbed and condensed out of the
mixture and recycled to the plant, while the
syngas will be mixed with waste gas streams
from other plant operations. These gases will
be treated in a thermal oxidizer and used to
raise steam. Meanwhile, in the PEM, silicon
from the waste will fall into the bath, forming
a relatively small amount of inert waste.
IET will own and operate the PEM, scheduled to start up in mid 2008 under an agreement with Dow Corning, says Surma. We
will generate about 10.5-million Btu/h of
syngas for steam and make 12-million lb/yr
of HCl, he says.
such metals in biomolecules of

living cells. Under the direction
of Isabel Sierra, professor at
the URJCs dept. of analytical
chemistry, researchers have
created new materials using
different types of silica and
modified them with 5-mercapto1-methylthiazole, which makes
them capable of binding lead
and zinc. These materials are
capable of undergoing several
cycles of absorption/desorption,
and the extracted metals can be
recovered for reuse.
Air-pollution control
Global revenues for suppliers
of air-pollution-control systems,
services, consumables and
components will reach $80
billion by 2015, up from about
$50 billion in 2007, according
to a survey by McIlvaine Co.
(Continues on p. 14)
Chemical Engineering www.che.com november 2007
13
10/26/07 3:12:11 PM
C hementato R
Slash downstream processing costs for producing

biologicals with this new chromatography technology
#JP4$DPOUJOVPVT4.$$
'PVSJOEJWJEVBMDPMVNOT
DPOUJOVPVTMZMPBEFEBOEFMVUFE
ast month at the BioProcess

-PBE
International
Conference
#BUDI
(Boston, Mass.; October 13),
DPMVNO
'VMMZMPBEFE
Novasep Process (Boothwyn,
DPMVNO
SFBEZGPS
Pa.; edlinks.che.com/6901-533)
FMVUJPO
launched a new technology
5PQMBZFST
for downstream processing of
GVMMZMPBEFE
biologicals. BioSC (Biophar1BSUJBMMZ
maceutical Sequential Chro1BSUJBMMZ
MPBEFE
MPBEFE
DPMVNOT
matography) uses a process
known as sequential multi-col-PXFSMBZFS
OPUMPBEFE
umn continuous chromatography (SMCC), which improves
3FBEZ
throughput and stationary
DPMVNO
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phase productivity for downstream processing up to four
times without compromising
product quality or yield, says the company. be working in a different step phase, such as
The technology is suitable for all types load, wash regeneration and so on.
of biomolecules, including monoclonal anBioSC overcomes the limitations of contibodies (mAbs), peptides, blood fractions ventional batch chromatography, where: the
and vaccines.
column loading is limited by its dynamic
SMCC resembles simulated-moving bed capacity; process flowrates are limited by
(SMB) chromatography in that it is a coun- mechanical stability of the packed bed; and
ter-current process where fluid circulates the stationary phase efficiency is limited by
continuously through a loop of columns, saturation of the resin binding sites. Initial
with feed and eluent being added to cer- modeling studies of a commercially relevant
tain columns, while fractions of interest are mAb process clearly indicate the potential of
recovered sequentially from each column a BioSC-based continuous downstream pu(diagram). The key difference is in SMCCs rification process to reduce the overall capiflexible scheduling of each of the multiple tal by up to 30%, equating to a cost of goods
columns and the ability to asynchronously reduction of about 49%, with water usage reand flexibly schedule each of the multiple duced by up to 78% and overall downstream
columns, which enables complex, multi-com- processing costs reduced by up to 69%, says
ponent separations, says Stephen Tingley, managing director Andrew Sinclair. The
vice president of sales and marketing. This first commercial unit is expected to go onmeans that each column can simultaneously stream next year.
Japanese water-treatment filter enters U.S. market boasting

no need to replace granular filter media ever
ast month at Weftec.07, the Annual Water

Environment Federation Technical Exhibition and Conference in San Diego, Nihon
Genryo Co., Ltd. (Kanagawa, Japan; edlinks.
che.com/6901-534) launched for the first time
to the North American market its Saito Tank,
a granular water filtration system that never
requires filter media replacement. Since traditional systems require filter media to either be disposed or externally recycled and
use more than twice the volume needed for
backwash water, the Saito Tank will pay for
itself within a 3 to 5 year range, says Yasuhiro Saito, Nihons president.
To achieve such results, Nihon Genryo de14
veloped a built-in version of its patented filter-media cleaning principle used in filter rehabilitation work. The filter media wash each
other with a kneading action, so the Saito
Tank can remove even stubborn sludge without damaging the filter media. Meanwhile,
since there is no need to dispose of used filter
media as industrial waste, the system is helpful in achieving zero emission standards.
The Saito Tank is well established in Japans
chemical process facilities, and has recently
been installed in facilities throughout Korea
and the European Union. Nihon Genryo holds
a worldwide patent on the technology and is
actively seeking North American distributors.
-PBEJOH
DPOUJOVFT
1BSBMMFM
FMVUJPO
N"C
GSBDUJPO
DPMMFDUJPO
5P8BTUF
5P8BTUF
(Continued from p. 13)

(Northfield, Ill.; edlinks.che.
com/6901-540). The market
will be driven by regulations
and programs to decrease
emissions of greenhouse
gases, says the report.
EPA settlement
American Electric Power (AEP,
Columbus, Ohio; edlinks.che.
com/6901-541) has agreed to
cut its emissions of air pollutants by 813,000 ton/yr at an
estimated cost of more than
$4.6 billion in a settlement
with the U.S. Environmental
Protection Agency (EPA,
Washington D.C.) and the U.S.
Department of Justice. The
company will also pay a $15million penalty and spend $60
million on projects to mitigate
the adverse effects of its past
excess emissions.
The settlement, which also
involves a coalition of eight
states and 13 citizen groups, is
the single largest environmental enforcement settlement in
history, according to EPA. It
resolves a lawsuit filed against
AEP in 1999, alleging that the
company violated the New
Source Review requirements
of the Clean Air Act.
Under the agreement, AEP
will install equipment to control
emissions of sulfur dioxide and
oxides of nitrogen (NOx) on 16
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C hementato R
A fast way to measure phase fractions

in multiphase flow
n the chemical process industries (CPI),

multiphase flow regimes in reactors, bubble columns, pipework and elsewhere in
plants determine process efficiencies and
safety. As a result, a considerable number of
intrusive and non-intrusive techniques have
been developed to recognize phase fractions.
However, such techniques are very expensive and complex (such as tomography) or
provide only localized, qualitative information (such as local probes and cameras). Several years ago, a wire-mesh sensor based on
electrical conductivity was developed at the
Dresden-Rossendorf Research Center (FZD;
Dresden, Germany; edlinks.che.com/6901535) that overcame many of the drawbacks
of alternative methods, but only conducting
media could be monitored with the device.
Now, researchers at the Institute of Safety
Research at FZD have constructed a wiremesh sensor based on electrical capacitance,
which can be universally applied to all liquid and gas phases, making it applicable to
many industrial processes, says researcher
Marco Jose Da Silva. As in the conductivity
sensor, the capacitance wire-mesh sensor
consists of a set of wire electrodes stretched
across a vessel or
pipe in two slightly
separated planes (diagram). The capacitance
is measured between
the electrodes at the
crossing points, which
in turn, is a measure of
the dielectric constant
of the material flowing
through the grid. The
associated electronics
are optimized to measure capacitances in
the range of a few femtofarad (1015 F).
The system can measure the phase-fraction distribution in a flow cross section with
high spatial and temporal resolution (graph).
Furthermore, the sensor is able to measure
nonconducting and slightly conducting fluids. The technology can be applied to pipe or
vessel diameters from 5 mm up to a meter.
Investment costs for the sensor and electronics are expected to be reduced from the
prototypes 30,000 when mass-produced,
says Da Silva.
This catalyst may open the door to green copolymer of CO2
echnology to copolymerize carbon dioxide and propylene oxide (PO) was first
discovered in 1960s, but has not been commercialized due to the formation of cyclic
propylene carbonate (CPC) by a back-biting reaction, which leads to the formation
of unstable, low-molecular-weight copolymers. This limitation has essentially been
eliminated, thanks to a new catalyst developed by Professor Kyoko Nozaki at the
Department of Chemistry and Biotechnology, Graduate School of Engineering, the
University of Tokyo (Japan; edlinks.che.
com/6901-536).
The new catalyst a bis-(piperidinyl
methyl)-salen cobalt(III) complex with two
acetate ligands is synthesized by the reaction of cobalt acetate with the corresponding disalicylidenediamine, followed by oxidation in the presence of an excess amount
of acetic acid and air. The catalyst enables
the selective formation of copolymers with
alternating CO2 and an epoxide, such as PO,
1-butene oxide, and 1-hexene oxide.
For example, the catalyst has been used
to make a copolymer of regularly alternat16
ing CO2 and PO molecules with a numberaverage molecular weight of 26,500. The
reaction takes place in a DME (1,2-dimethoxyethane) solvent under 14 bar CO2,
with a 99% yield and a 97% selectivity.
CPC formation is suppressed by capping
the copolymer terminus by a proton coming from the piperidinium branch of the
catalyst. This copolymer has a high (250C)
decomposition temperature, making it suitable for injection molding. It also has a low
birefringence, a high gas permeability and
flexibility, and is biodegradable.
The commercial production of such copolymers provides an opportunity to utilize CO2, thus reducing the amount of this
greenhouse gas released into the atmosphere. Taking this opportunity, a project
has started to study the commercialization
of aliphatic polycarbonates made from CO2
and epoxides. Supported by the New Energy
& Industrial Technology Development Organization (Kawasaki, Japan), the project
involves three universities (including the
University of Tokyo) and four companies
from Japan.

of its coal-fired power plants in
Indiana, Kentucky, Ohio, Virginia and West Virginia. The
controls are expected to cut
total NOx emissions at these
plants from 231,000 ton/yr in
2006 to 72,000 ton/yr by 2016,
and reduce SO2 emissions
from 828,000 tons in 2006 to
174,000 ton/yr by 2018.
Metals complex
Last month, UC Rusal (Moscow, Russia; edlinks.che.com/
6901-542) signed an agreement with the government of
Russia's Saratov region for
the construction of a major
energy and metals complex,
which includes the expansion
of the Balakovsky nuclearpower plant. UC Rusal will
build the fifth and sixth reactor blocks, generating 2,000
MW, and the construction of a
1.05-million m.t./yr aluminium
smelter claimed to be the
world's largest. A feasibility
study is expected to be completed by the end of next year.
Li-ion betteries
Evonik Industries AG (Essen,
Germany; edlinks.che.
com/6901-543) is acquiring a
20% stake in Li-Tec Vermgensverwaltungs GmbH &
Co. KG (Kamenz, Germany).
With its participation in Li-Tec,
Evonik is now starting mass
13-18 CHE 11-07.indd 16
10/26/07 3:13:16 PM
17 CHE 11-07.indd 17
10/25/07 6:34:05 PM
C hementato R
A second major plant

for a new PO process
abigh Refining & Petrochemical Co., a 50:50 joint venture of $VNFOF

Saudi Arabian Oil Co. (Dhahran,
both Saudi Arabia) and Sumitomo
Chemical Co. Ltd. (Tokyo, Japan;
edlinks.che.com/6901-537), is con)0
structing a new plant to produce
200,000 m.t./yr of propylene oxide
(PO). When the plant starts up
next year, it will be the second commercial plant to use a byproduct)
free process developed by Sumitomo Chemical (CE, October 2000,
p. 17), the first being a 150,000m.t./yr plant at the Chiba, Japan,
factory, which was expanded to
200,000 m.t./yr in 2005.
Conventional routes to PO either generate large volumes of: wastewater (the chlorohydrin process), styrene monomer (the
Halcon process) or tert-butyl alcohol (the
isobutene-oxidation process). In contrast,
water is the only byproduct generated from
Sumitomos PO process.
According to published patents and reports, Sumitomos PO process is based on a
cumene feedstock. In the process (diagram),
cumene is first oxidized in air (without a
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catalyst) at 90130C and 110 bar, into

cumene hydroperoxide (CMHP) with a selectivity of over 95%. Propylene is then epoxylated with CMHP in a fixed-bed reactor
over the companys proprietary titaniumsilica catalyst at 25200C and 1100 bar,
into PO (selectivity over 95%) and alphadimethylbenzyl alcohol (CMA). CMA is
hydrogenated into cumene which, together
with unreacted cumene, is recycled into the
process.
A less expensive way

to produce titanium
new process to produce titanium, called

the TiRO process, has been developed by
a team from CSIRO (Melbourne, Australia;
edlinks.che.com/6901-538) through its Light
Metals Flagship. The process is said to halve
the cost of producing titanium metal components by: 1) Replacing the conventional
Kroll-batch process with a more continuous
process based on fluidized-bed (FB) technology; and 2) Using Tis powder metallurgy to
circumvent the mill-based manufacturing
processes that are currently required.
Team leader Grant Wellwood says the
overall chemistry of the TiRO process is the
same as that of the Kroll process, whereby
TiCl4 reacts with Mg to form Ti and MgCl2.
The novelty of the TiRO process is an operating window that enables the reaction to
occur at a lower temperature and continuously in an FB. The temperature window is
defined by the melting points of Mg (650C)
and MgCl2 (712C). The intermediate product from the reaction stage of the TiRO pro18
cess is a composite of MgCl2 (continuous

phase) and Ti particles (discrete phase). In a
second stage, the two phases are separated.
Magnesium and liquid TiCl4 are conveyed
(stoichiometrically) into the base of the reactor by a high-purity argon gas stream.
The centrally discharged solid product is in
the form of spherical pellets with an average particle size around 400 m. The composition of the intermediate composite is 20
wt.% Ti and 80 wt.% anhydrous MgCl2. The
Ti deposits as discrete, easily separated particles with an average size of about 4 m,
which are uniformly dispersed throughout
the MgCl2 matrix.
The team is using a simple stainless-steel
reactor designed to operate with about 500
g of bed, and has a nominal throughput of
200g/h of Ti. The researchers have achieved
their proof-of-concept stage metal quality target, and expect to meet commercial
grade quality upon scaleup to the next
scale plant (greater than 2 kg Ti/h).
production of battery components. Evonik has developed

materials for use in high-performance storage systems
under the tradename Litation
(electrodes) and Separion (a
heat-resistant ceramic separator). Since January 2006,
Evonik and its wholly owned
subsidiary, Litarion GmbH,
have been constructing an
electrode-production plant
for large-volume lithium-ion
batteries at the Li-Tec site in
Kamenz. The plants annual
production capacity is enough
to make about 30,000 batteries for hybrid vehicles.
Microbial testing
A molecular testing method
that attains a viable count of
microbial organisms in as little
as 4 h compared to the typical
314 d needed by standard
methods, has been commercialized by Lonza AG (Basel,
Switzerland; edlinks.che.
com/6901-544). The genetics-based (RNA targetting) microCompass System is said to
offer improved sensitivity and
detection of bacteria, yeast
and mold at a high-throughput
level by batching up to 96
samples at a time.
Solar cells
A program to develop ionic
liquids and formulations to
improve the performance and
efficiency of solar cells has
been initiated by BASF AG
(Ludwigshafen, Germany)
and G24 Innovations, Ltd.
(G24i; Cardiff, Wales; edlinks.
che.com/6901-545). G24i
produces photovoltaic cells
that use the same principles
as photosynthesis in plants,
which makes them sensitive
to "far more" of the visible
spectrum of light than conventional solar cells. Instead of
chlorophyll, a ruthenium dye
is used to convert light into
electrical energy by a chemical process. The dye-sensitized thin-film technology was
originally developed at the
Swiss Institute of Technology
(Lausanne, Switzerland).
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10/26/07 3:13:46 PM
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10/26/07 10:42:33 AM
Microsoft
Newsfront
Its a
Small
World
Managing the
chemical supply chain
in a global economy
requires visibility
and collaboration
he globalization of the economy

is making the world a smaller
place and leading businesses
the chemical process industries
(CPI) included to source, produce
and sell material in foreign lands. Politics aside, the trend has the potential
to wreak havoc on the supply chain,
logistics and transportation operations of chemical corporations unless
strategies that increase collaboration
and visibility while handling event
management are put into place.
Supply chain challenges
Globalization has given rise to the

so-called BRIC economies, as Brazil,
Russia, India and China (BRIC) begin
to take prominent roles in the global
chemical market due to their ability
to offer lower material, production
and labor costs, according to a recent
paper titled, Issues and Competitive
Strategies for the Chemical Industry,
by enterprise software and technology
provider CDC Systems (Atlanta, Ga.).
The emergence of these markets
has placed significant pricing and
supply chain pressure on U.S. chemical manufacturers, forcing them to cut
costs in order to remain competitive.
In addition, many chemical manufac20
Figure 1. Technology, such as the Microsoft Biz Talk Server 2006 R2, is helping
chemical processors manage their supply chains in an ever-changing global environment by making it easy to onboard foreign partners and business units
turers are buying from, or selling to,

companies in these regions, which creates much more sophisticated global
supply chains, says CDC. Some U.S.
manufacturers are also opening plants
or partnering with companies that
already exist in the region to share
intellectual property in order to take
advantage of lower production costs.
However, this approach also adds complexity to the supply chain as inventory and capacity are now being managed globally as opposed to regionally
in North American plants, according
to the paper.
This approach also creates the additional challenge of establishing a core
foundation of business processes that
can keep pace with the ever-changing global environment, says Brian
Willson, director for chemical industry business at Microsoft (Redmond,
Wash.). How do you easily connect a
new plant, new partner or acquired
company in a new region to the business processes that are already established? he asks.
Taking action
According to the experts, there are ways

to manage and overcome these global
supply-chain challenges, but thus far,
the CPI has been slow to embrace
them. Consulting firm Accenture (Chicago, Ill.) conducted a series of studies
on supply chain practices, and the most
recent, The 2007 Global Chemical In-
dustry Supply Chain Best Practices

Study, revealed that while companies
now appear to have more clarity about
their supply chain strategies and directions, change is slow, and actual results
have been relatively limited.
The study also showed that although 75% of respondents consider
supply chain a driver of operational
excellence or a source of competitive
advantage, the CPI has been slow to
advance it (see also Figure 2).
Based on input from study respondents, Accenture identified four focus
areas that provide opportunities to
improve the supply chain and make it
work in this global economy. First and
foremost, says Christopher F. Lange,
senior executive, global-supply-chain
leads for chemicals and natural resources at Accenture, is the increased
involvement of supply chain function
in commercial decision making. You
need to put forth the premise that if
you want to improve supply chain operations, those operations need to be
involved in the commercial decision
making what products to produce,
where to produce them, what customers to serve and how to serve them,
he says. These decisions need to be
made through modeling for better financial results. Who better than the
supply chain folks to look at the cost
drivers and understand the trade-offs
of such decisions?
Lange says that this type of col-
20-24 CHE 11-07.indd 20
10/26/07 3:03:46 PM
Views from an Industry

Supply Chain Leader
ow Chemical Co. (Midland, Mich.)

operates in 39 countries and has
plans for further expansion in
India, China and Saudi Arabia.
Company executives stay ahead of the
curve by successfully leveraging supply
chain management to achieve overall
business objectives, namely expanding
the company's international reach.
Chemical Engineering went to Don
Weintritt, global supply chain director
with Dows Supply Chain Technology and
Enterprise Center, to find out how the
company manages its expansive supply
chain.
Q: What are some of the biggest issues
when dealing with the global supply
chain?
A: We are constructed across areas that

can be described by three, integrated
supply chain work processes.
(1) Design and Modify Supply Chain:
We are using design and modify supply-chain work processes and enabling
technologies to provide breakthrough
technical and operational supply chain
designs across:
Regional cross-business network optimization design
Global business-specific network optimization design
Established market plant and facility
growth / consolidation redesign
Exchange, swaps, and tolls evaluation
and design
A: Ive bulleted the biggest global supply

chain issues.
Mergers and acquisitions, including

due diligence and Integration
Chemical transportation security
Joint ventures, divestitures
International trade
SC design for emerging growth MEGA

production complexes (loosely defined
as over $5 billion)
Transportation infrastructure
Rail competition
Payload optimization
Ocean vessel flexibility
Chemical transportation safety regulations and risk management
Sustainable supply chains
Massive shift in supply chain complexity
and volume on the horizon various
new business models being developed
and deployed
Q: What do chemical processors need
to do to improve their supply chain in
order to meet these challenges?
A: Chemical processors need to understand their supply chain environment, its
alignment to corporate strategy, and how
it integrates into supply chain design, operations and sustainability.
Dow embarked on a three-pronged initiative to further improve its global supply
chain. Our approach includes management of distribution safety and security
risks, to reduce the companys risk profile, and to provide industry leadership
to enhance public confidence in chemical
supply-chain safety and security. Dows
initiative is focused on best practice implementation, improvement and innovation. Through this approach Dow evaluates and understands its risks, prioritizes
the risk mitigation efforts, develops project plans with stakeholders and finally
incorporates technical innovation and
collaboration into each project.
Q: Can you provide some details about
how your supply chain operates?
Distribution models
Macro regional and global material
trade flows
Across these value chains we have (2)
Demand Driven Business Operations
work process and tools to develop the
constrained and unconstrained supply
and demand balances and manufacturing/transportation plans. Finally, we
use (3) the Material Flow work process
and tools to manage the flow of materials and information from our suppliers,
through our manufacturing and distribution assets and channels to market, to our
customers. There are a number of other
supporting technologies and expertise/
operating groups such as warehouse
and terminal management, RFID and
track and trace, bar coding and labeling
systems, our modal operations groups
and others. But we operate across the
supply chain described by these three
main segments.
Q: Do you have any advice for other processors on beginning to make improvements?
A: Yes, first you must understand your
supply chain environment, and then
understand your corporate strategy for
network design and sustainability. Beyond that its important to evaluate risks
and prioritize your risk mitigation effort.
Next its necessary to develop a project
plan with stakeholders. Once all that is
in place, technical innovation and collaboration should be incorporated into
each project.
Bioengineering
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Segregation does not occur, even
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Applications for the Inversina: analytical labs, metal finishing shops, powder
metallurgy and nuclear industry,
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ceramics, cosmetics, dental products,
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20-24 CHE 11-07.indd 22
2007 COADE, Inc. Autodesk, the Autodesk logo, and AutoCAD are registered trademarks of Autodesk, Inc.
Piping
Steel
Cable trays/ducting
Collision detection
Equipment
Bills of material
Isometrics
Flow schematics
Instrument loop diagrams
Bi-directional links to analysis programs
Walkthrough and visualization
Newsfront
laboration requires involvement of
the supply chain, manufacturing and
commercial entities in a chemical
company. You need input from everyone so you understand what customers want and combine that with
the knowledge of the plant and the
variability in the now-global supply
chain, he explains. Then you need to
model it and come up with optimal answers that determine whether you can
produce that product well for a profit
or whether it adds non-prime material
to your inventory.
The next focus should typically be
planning, particularly demand planning and forecasting, says Lange. If
you know what the customer wants,
you can factor and coordinate those
needs into production schedules that
mesh with raw material schedules
and then coordinate that with transportation. If planning is done properly, improvements can quickly ripple
through the supply chain, he says.
Companies should look next at functional areas such as transportation
and material sourcing. We suggest
first simplifying the processes and
then standardizing them across the
board, says Lange. A lot of chemical
companies are really portfolio management companies with many different
businesses operating under a single
parent company. So, they need to seek
out common supply-chain characteristics across the family of business units
and leverage them.
And finally, most companies need
to improve supply chain talent. You
need to look within the company, and
then look externally to find the most
qualified people to run the supply
chain, and then improve the training
for those people.
Tools for improvement
To help chemical processors take action, technology providers are developing products that help facilitate
collaboration, visibility and event
management to assist with planning
for supply chain events, both internally and externally.
When it comes to internal collaboration, we now see that the logistics
guy is just as important as the marketing guy, and these groups need
to be talking, says Ray Adams, field
Cross-Business-Unit Collaboration
and Sales and Operations Planning
/P
DPNNVOJDBUJPO

1FSJPEJD
DPNNVOJDBUJPO

4IBSF
EBUBJOUFHSBUF
QMBOOJOH

Figure 2. Chemical companies are

striving to collaborate internally between
the supply chain and sales and operations units. In the areas of demand/supply balancing, or sales and operations
planning, 53% of respondents to Accentures The 2007 Global Chemical Industry Supply Chain Best Practices Study,
said that related business units routinely
share demand and supply data. Only 10%
said they had no internal collaboration
services director, industry business

unit, chemicals with SAP Americas
(Newtown Square, Pa.). So we are
striving to provide a common platform
and common mechanism that allows
them to be looking at the information
in respective terms that are meaningful to them. We now offer the Sales
and Operations Planning product on
a service-oriented architecture, which
means it is a standalone solution that
doesnt require SAP to be running in
the back office.
On the flip side, SAPs Supply Network Collaboration supply chain suite
is intended to extend the supply chain
externally to include suppliers, customers and toll manufacturers. As a
chemical manufacturer, you cant expect your suppliers to be running SAP..
However, you can expect them to have
internet access and the ability to use
it to hop onto a portal and enter an advanced shipping notice, says Adams.
If they are willing to do that, you can
have visibility into advanced shipping
notices on purchase orders.
This suite provides links so outside
vendors can perform such functions
through a standard web portal with
a log-on ID. For higher volume transactions, XML exchanges can be performed in a way thats fully automated
and fully loaded directly into a chemical manufacturers system.
10/26/07 3:04:38 PM
BIAZ-1-3-Che-Eng-07-2
a lot of expense. Specifically, to the supply chain,

it increases visibility of
information, which can
Accenture
edlinks.che.com/6901-561
help processors make
Aspen Technology
better decisions, lower
Axxom Software AG
the cost of inventory
CDC Software
and make better foreDeacom, Inc.
casts. And in this type
Intergraph
of emerging economy, the
Microsoft
faster they can enter a
OSIsoft
SAP Americas
market and [bring] onWAM Systems
board new partners, the
better market share they
Basic information such as a cus- can achieve over time by being there
tomer forecast for products can be first, says Willson.
used to generate raw material reSolutions that facilitate visibility
quirements and supply plans. Those and event management are also crucial
requirements can be automatically to supply chain improvements. Visconfigured into purchase orders for ibility and event management tools
suppliers, which can be sent electroni- are needed to provide early warning
cally so the suppliers can see them and and insight into pending issues, such
respond automatically. This provides as a customer order that wont ship on
suppliers with an opportunity to re- time, says Jack Weiss, CEO of WAM
spond with an alert if theres an issue, Systems (Plymouth Meeting, Pa.).
so the chemical processor can take acWhile its always been important
tion, such as going to another supplier. to have visibility into customer promThis type of technology-enabled con- ises, order ship dates and the impact
tingency planning allows a chemical that late shipments of supplies and
processor to respond to changes in the materials will have, globalization emsupply chain rapidly, notes Adams.
phasizes the need for visibility and
External collaboration is also needed event management. With globalizato unite externally located businesses tion, supplies or materials often come
within the chemical manufacturers with a four-week lead time, so having
own portfolio. When you think about visibility early that a late supply will
connecting the business processes impact manufacturing and fulfillment
around the country or around the globe, of a customer order, gives processors
one of the challenges is just the tech- time to react, says Weiss.
nology infrastructure costs necessary
And, some software tools are deto connect disparate business applica- signed to tie all this collaboration,
tions, says Microsofts Willson. The visibility and event management
Microsoft BizTalk Server 2006 R2 (Fig- into one package. AspenOne Dyure 1) was developed as a service-ori- namic Supply Chain Management
ented architecture to provide a quick, for Chemicals from Aspen Technology
easy and economical way to connect (Burlington, Mass.,), was developed to
processes and systems both inside the help chemical processors balance supfour walls even when the four walls ply and demand on an enterprise-wide
extend overseas and outside with scale (from raw materials to finishedcustomers and suppliers, he explains.
good inventory) based on dynamic
The service-oriented architecture market conditions. The developer says
approach provides a way to expose all the software helps users identify and
the applications and orchestrate busi- react to problems via exception resoluness processes, such as order manage- tion and alerting capabilities, develop
ment and plant floor scheduling across optimal forecasts by incorporating
the landscape. This creates efficiencies statistical methods with collaboration
and enables processors to react to the between internal and external stakenew global environment that might holders and re-plan on an enterpriseinclude new partners and plants and wide basis.
bring new members onboard without
Software developers, such as Axxom
1.3.2007
11:30
Page 1
Supply Chain Technology

and Service Providers:
20-24 CHE 11-07.indd 23
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Where the Know-how is

20-24 CHE 11-07.indd 24
Newsfront
Software AG (Munich, Germany), are
adding functionality to help improve
visibility in the chemical supply chain.
A new version of ORion-PI Value Network Optimization optimizes supply
chain networks via a range of functionalities, including a geographical
view of the network that involves a
structural display of all logistics processes and value flows, allowing process and material flows in the supply
chain to be visualized quickly and
transparently. This version also offers
extended possibilities for integration
with other systems and applications.
The improved link to MS-Excel permits transfer of all relevant data, and,
with the aid of a certified interface,
data can be synchronized directly with
SAP applications.
No matter what the software tool, experts agree that adding collaboration,
visibility and event management to the
supply chain can provide vast benefits
for the chemical processor who uses it
to manage its suppliers and customers,
get better forecasts, improve planning,
react faster to unplanned events and
improve inventory performance. Ultimately these actions free up working
capital and improve customer responsiveness, leading to more sales.
Improving transportation
Visibility is also of the utmost importance when it comes to managing

transportation. Following the trend to
outsource logistics and transportation
to third-party providers, many chemical processors have found themselves
with large bills and less of the information needed to explain the costs, which
are now rising due to stricter regulations and increasing fuel prices. This
way of doing business doesnt provide
processors with the means to do an
internal strategic analysis concerning transportation costs, says SAPs
Adams. For this reason, we decided
to build a transportation solution, the
TM60, which stands alone and contains all the necessary information.
Improved transportation solutions,
such as the TM60 and our Optimizer
Engine, which handles transportation optimization, are what we call
game changers because the benefits of
improving transportation are many,
says Adams.
In the general area of carrier selection, todays solutions can provide

visibility into information that helps
processors determine who is the best
carrier for a particular route. They
can get a 10 to 30% improvement on
cost from better carrier management,
says Adams.
Other key benefits come from load
consolidation. Running our Optimizer Engine helps show processors
where they can combine loads, which
results in savings because the truck
is always full, which minimizes costly
empty miles, says Adams.
And, those railcars sitting unused on
a track for two weeks? Technology can
help eliminate that problem as well.
As they begin to employ technology
that provides information and visibility, processors can begin to proactively
keep these assets moving and reduce
their demurrage costs, says Adams.
It is expensive to have a storage tank
car sitting on a track somewhere, but
if they have visibility and know where
it is, they can keep it moving and
avoid charges. For a large company
with thousands of railcars, demurrage
charges can be in the multi-millions
of dollars. If you can use technology
to cut that in half, the savings can be
significant.
With increased competition, customers are demanding higher quality
and better service, and supply chain
and transportation management are
key to providing these characteristics,
even in a global environment. If you
can perform better than the competition, you can differentiate yourself,
explains Weiss. Leaders in chemical
supply-chain management can offer
shorter lead times and flexibility to
their customers, which is a real advantage.
What it all comes down to is using
your reactive and well-coordinated
supply chain to react to a customers
unexpected event and save the day for
them, Weiss says. While this is difficult in todays environment of tight
inventory and distant suppliers, if you
have the tools to spot and react to issues and come up with optimal supply
chain and delivery strategies, you will
serve your customers well and the rewards will be plenty.
n

Joy LePree
10/26/07 3:05:33 PM
Newsfront
KEEP CONTROL OF
YOUR DUST
Energy saving, emission regulations,
explosion protection and finer filters
combine to drive the market in
particulates removal
Farr Air Pollution
Micro Air
etter control of baghouses and

cartridge-type dust collectors
can pay dividends in energy savings, longer filter life and
effort spent in tracking environmental compliance. Thats the
message from Richard Kapcha,
a control specialist with MikroPul
(Charlotte, N.C.), which manufactures
a wide range of dust collection equipment. Until the early 1990s we were
supplying baghouses with cleaning
cycles based on fixed time intervals,
Kapcha says. Many of these timer
systems are still in use. Changing to a
cleaning routine based on differential
pressure can save a large plant tens of
thousands of dollars a year.
By cleaning filters only when they
need it, differential-pressure control
systems lengthen filter life as well as
saving compressed air, Kapcha adds.
MikroPuls recently launched PulsePro
EC control unit (photo, right) uses reliable solid-state pressure sensors to
check the cleaning status of one or more
dust collectors, and relay the results to
a control room. As well as managing
the cleaning cycle, the PulsePro EC
monitors compressed-air use, allowing
it to detect energy-wasting valve diaphragm failures. And, it also measures
and records particulate levels in the
exhaust air. As reporting requirements
become more stringent, Kapcha says,
the ability to log this information automatically saves time and paperwork
headaches; it also detects bag failures.
A new particulate emission monitor
and baghouse leak detector from Fil-
FilterSense
United Air Specialists
Midwesco
Filter
MikroPul
The MikroPul PulsePro EC (above) saves

compressed air by controlling baghouse
cleaning based on differential pressure; it
also checks for leaky air valves and monitors downstream dust concentration
This induction-type particle detector from
FilterSense (second from top) is said to be
more reliable than sensors that are based
on optics or triboelectricity
The Twister (top) from Micro Air is a compact solution for local dust removal; Farrs
HemiPleatHE cartridges (right, top) have
high removal efficiency and are easy to
clean; United Air Specialists has launched
these nanofiber cartridges (right, center);
filter bags from Midwesco Filter (right)
boast ease of changing
25-28 CHE 11-07.indd 25
25
10/26/07 3:08:14 PM
Electrostatic precipitators fight back
Newsfront
n 2007 power plants, mines and industrial

companies spent $6.1 billion on fabric filter
equipment, systems, and elements for exhaust
gases, according to McIlvaine Co. (Northfield, Ill.;
www.mcilvainecompany.com).
In the continually updated online report Fabric
Filter and Elements World Markets, McIlvaine
predicts that sales will increase at 6% annually
over the next five years.
One reason for this healthy growth is the rapid
expansion in Asia of steel mills, foundries, chemical plants, and cement producers.
Another factor is regulatory pressure, which
is driving coal-fired power stations and cement
plants to move from traditional dry electrostatic
precipitators (ESPs) to more-efficient fabric filters,
McIlvaine says.
Despite this, the ESP market is growing too,
though more slowly. 2007 worldwide sales of
ESPs totaled $3.9 billion. Of this figure, $600 million was for wet systems, whose higher efficiency
on small particles is allowing them to gain ground
compared to dry ESPs, McIlvaine says.
Suppliers of ESPs as well as fabric filters to the
terSense (Beverly, Mass.;

photo, p.25) incorporates
automatic
self-checking
to improve performance
and eliminate manual
calibration, which would
otherwise be required by
the EPAs MACT and CAM
regulations governing fabric-filter dust collectors.
Smart diagnostics and a
proven induction sensing
technique increase reliability compared to sensors
based on measurements of
opacity or triboelectricity,
FilterSense says, making
the unit ideal for difficult
applications such as coal,
steel, cement, carbon black, lead smelters and pharmaceutical spray dryers.
The company also supplies pass/fail
particulate detectors and non-clogging
pressure transmitters.
To clean filter bags and cartridges
26
power and cement industries include Wheelabrator Air Pollution Control Inc. (Pittsburgh, Penn.),
part of Siemens Power Generation since 2005;
Alstom (Levallois-Perret, France, and Windsor,
Conn.); and Clyde Bergemann (Baltimore, Md.).
In July of this year Environmental Elements Corporation (Baltimore, Md.), now a subsidiary of
Clyde Bergemann, won a contract worth more
than $4.5 million to supply an ESP to Arkansas
Kraft, a division of pulp and paper company
Green Bay Packaging. Replacing an existing 30year-old unit on a recovery boiler, the new ESP
will improve both environmental performance
and energy efficiency, by allowing the plant to
burn high-solids liquor from the pulp process.
In June, Wheelabrator won a contract from Prairie State Generating Company LLC for a complex
multi-emission control system at a 1,600 MW
power plant and coal mine planned for Lively
Grove, Illinois. Wheelabrator will supply dry ESPs,
an activated carbon injection system for mercury
control, a hydrated lime injection system for sulfur
trioxide control, wet FGD systems, and wet ESPs
for acid mist and fine particulate control.
effectively using the minimum of

compressed air, Asco Joucomatic Numatics (lbronn-Drrn, Germany)
has launched a 1.5-in. version of its
successful type 353/800 Power Pulse
solenoid valve. Specifically designed
for dust collectors, the valves feature
a patented piston design that enables
significantly faster opening and closing, quieter operation, and lower air
consumption with no compromise
in cleaning performance, the company claims. Options include a rapid
mounting system, and a version with
a remote pilot valve for applications
where space is at a premium. The
standard design can operate at temperatures up to 85C, with a 150C
model available, and version are available for hazardous atmospheres.
Changing regulations affecting dust
filters and baghouses go beyond environmental protection, notes Sal Campos, marketing services manager with
Farr Air Pollution Control (Jonesboro,
Ark.). Recent updates to standards
published by the National Fire Protection Assn. (NFPA; Quincy, Mass.; www.
nfpa.org) have increased the range of
applications for which dust filters and
baghouses require explosion venting,
he says. As a result, Farrs flagship
Gold Series cartridge dust collector is
now available with a built-in explosion
vent. The new multi-ribbed X-vent,
which is made of stainless steel and
can be retrofitted to existing dust collectors, meets NFPA and ATEX standards. Units in the modular Gold Series
range in size from single cartridges up
to 150,000-CFM (ft3/min) housings containing 140 cartridges, Campos says.
Finding a finer filter
Instrumentation and explosion protection notwithstanding, key to the performance of any type of cartridge or
fabric filter is the filter medium chosen. Farrs Gold Series dust collectors,
for instance, are fitted with HemiPleat
filter cartridges, which are resistant to
moisture, highly efficient (99.99% for
particles of 0.5 m and larger), and
have a wide, uniform pleat spacing
for maximum dust capacity and easy
cleaning. The latest HemiPleat HE
(High Efficiency) cartridges (photo,
p.25) go one better, with an efficiency
of 99.999% for particles down to 0.5
m, and a MERV (Minimum Efficiency
Reporting Value) of 15. The company
claims that these typically provide
twice the life of standard cartridges,
at half the pressure drop.
According to some manufacturers,
nanofibers provide better filtration
performance and cleanability than the
standard fibers of cellulose acetate,
glass and thermoplastics traditionally
used for cartridges and filter bags.
United Air Specialists (UAS; Cincinnati, Ohio) recently launched a range
of cartridge filters based on nanofibers
just 70150 nm in diameter (photo,
p.25); the company says this is around
half the diameter of the nanofibers in
competing products.
UAS marketing manager Lisa Wilhelmus says the MERV 15-rated nanofiber filters typically have twice the life
25-28 CHE 11-07.indd 26
10/29/07 2:01:22 PM
This dust removal unit from

Cyclonaire (far left) targets
pneumatic conveying systems.
Donaldson Torit
Donaldson Torit, pioneer of

nanofibers, recently launched
a new, tougher, version for cartridges and bag filters (left)
Clyde Bergemann shows that
electrostatic precipitators
remain an important dust-removal technology (right)
Another design of pleated bag is

MikroPuls Mikro-Pleat, said to be
the only snap-in bag with an integral
venturi. The companys Grapoid tool,
which is powered by a cordless drill,
allows snap-in pleated and felt bags
to be removed in around 10 sec. each,
with little effort. For even easier bag
changing, MikroPul Pop-Top 2 bags
replace standard snap-in bags and
seal with simple foot pressure.
Choose the right housing
Important as the filter bag or cartridge is, a well-designed housing is
also essential to create an effective

installation. AAF International (Louisville, Ky.) has launched the ArrestAll
AR Series self-contained, shaker-type
dust collector for intermittent and
light-duty applications. The compact
unit has a top-mounted fan with easy
access for servicing, 16 filter pockets
as standard, an automatic shaker
mechanism with an adjustable timer
for cleaning, and a silencer; an integral final HEPA filter is optional. A
side door makes filter changing easy,
and a tough powder coating protects
the metal parts.
PflXi\èZ_Xi^\]fik_\gifZ\jj%
N\jlggcpk_\dXkZ_è^Zfdgi\jjfi%
Pharmacology, Chemical, Cosmetics

PC3E
of standard cellulose and 80/20 cellulose/polyester cartridges, and use up to

60% less compressed air for cleaning.
The filters are durable, because the
nanofibers have very good adhesion
to the substrate material, Wilhelmus
says, and the distribution of nanofibers is very even, so there are no large
holes that can let particles through.
The Donaldson Torit division of filter
systems manufacturer Donaldson Co.
(Minneapolis, Minn.) has been making nanofiber filters for 25 years, and
in January this year launched an improved version of its Ultra-Web product. With a layer of nanofibers atop a
spunbond polyester substrate, UltraWeb SB is a tough filter medium that
is ideal for fibrous or abrasive dusts,
explains marketing manager Julie
Rumsey. Getting perfect adhesion to
the backing material was a technical
challenge, she says, but the resulting resin-free construction ensures
good resistance to heat, moisture and
chemical attack, while wide pleats aid
cleanability. Ultra-Web SB is available
in both cartridges (photo, above) and
filter bags. Donaldson Torit also offers
cartridge filters with Ultra-Web nanofibers on cellulose and synthetic substrates, as well as PTFE membrane
filters with spunbond substrate.
For installations using bag filters
instead of cartridges, Midwesco Filter Resources, Inc. (Winchester, Va.)
says its Seal-Tite II pleated elements
(photo, p.25) are easier to install than
any other bottom-load filter bag on the
market today. The proprietary sealing
and clamp system saves installation
time, creates a virtually leak-proof
seal, and makes incorrect installation
practically impossible, the company
claims. The washable filter bags are
long-lasting, thanks in part to the
elimination of inlet abrasion problems,
and offer dust removal efficiencies up
to 99.99%.
Clyde Bergemann
neubert-werbung.de
Cyclonaire
Quality
without compromise
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25-28 CHE 11-07.indd 27
27
10/26/07 3:09:39 PM
Doyens of dust disposal
Newsfront
AAF International
Alstom
Asco Joucomatic
Clyde Bergemann
Cyclonaire Corp.
Donaldson Torit
Farr Air Pollution
Control
FilterSense
Pneumatic conveying specialist Cyclonaire Corp. (York,

Neb.) has launched a range
of environmental protection
products under the name 445
Technology, in reference to the target of limiting atmospheric carbon
dioxide to 445 ppm suggested by the
U.N. Intergovernmental Panel on Cli-
mate Change. The range includes the

C&C automated dust reclaim system
(photo, p.27), which captures dust
from silo filling operations. Other
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28
Micro Air
Midwesco Filter
Resources
MikroPul
Scientific Dust
Collectors
Sly, Inc.
United Air Specialists
Wheelabrator
products collect dust from the unloading and filling of sacks and intermediate bulk containers (IBCs), and
from pneumatic conveyors.
Micro Air (Wichita, Kan.) makes
cartridge-type filters units with capacities up to 100,000 CFM, explains
national sales manager Jim Orr. The
companys recently-launched RP-1
Twister (photo, p.25) is a compact
unit rated at 1,000 CFM that combines an upstream cyclone with a
cartridge filter. The unit measures
just 18.5-in. dia. and 64 in. high.
Cleaning is via Micro Airs exclusive
Roto-Pulse cartridge cleaning system, which is said to clean 100% of
the cartridge area. Applications include capturing dust from grinding
operations and bag filling.
Among the range of dust collection devices available from Scientific Dust Collectors (Alsip, Ill.) are
two types of heavy-duty horizontal
cartridge units with reverse-pulse
cleaning: the SL and the SL-HR.
The SL is a compact housing for up
to 24 cartridges, and handles flows
of 1,80015,600 CFM. The more advanced SL-HR (High Ratio) is suitable for larger flows, operating at
flowrates of up to 1,000 CFM per cartridge. This is around twice the specific flowrate of the SL, and is made
possible through a patented cleaning
system and innovative cabinet design, the firm says.
For locations where compressed
air for filter cleaning is not available,
the RAC series of dust collectors
from Sly, Inc., (Cleveland, Ohio) may
be useful. Instead of an external compressed air supply, this design uses
an internal blower powered by an explosion-proof motor. A rotating cleaning arm carrying a series of nozzles
directs high-velocity air jets onto the
filter bags to remove dust. Sly RAC
dust collectors are available for air
flowrates of 4,50070,000 CFM. The
company also manufactures other
wet, dry and combination wet/dry
dust collection systems.
Charles Butcher
WG SPS ad_CE_half_2-07.indd 1
25-28 CHE 11-07.indd 28
3/1/07 11:03:02 AM
10/26/07 3:10:08 PM
Pump Selection
and Specification
Department Editor: Kate Torzewski
Centrifugal pumps
The most widely used pump in the chemical process industries for
liquid transfer is the centrifugal pump. Available in a wide range of
sizes and capacities, these pumps are suitable for a wide range of
applications. Advantages of the centrifugal style include: simplicity, low initial cost, uniform flow, small footprint, low maintenance
expense and quiet operation.

1SFTTVSF MCGJO
n choosing a pump, it is important to match a pumps capabilities with system requirements and the characteristics of the liquid
being processed. These factors include the inlet conditions,
required flowrate, differential pressure and liquid characteristics.
Generally, the quality of the liquid should remain unchanged after
passage through a pump. Therefore, material compatibility, viscosity, shear sensitivity and the presence of particulate matter in a
liquid are important considerations in pump selection.
Most engineering applications employ either centrifugal or
positive displacement (PD) pumps for fluid handling. These pumps
function in very different ways, so pump selection should be based
on the unique conditions of a process.
belong to a greater category of kinetic pumps.

A simple way to narrow down pump styles is to determine the
required capacity that your pump must handle. Based upon a
required capacity in gal/min. and a pressure in lbf/in.2, the pump
coverage chart below can help engineers focus their selection to a
just a few pump styles.
)FBE GUPGMJRVJE
PUMP SELECTION

Positive displacement pumps

Though engineers may be first inclined to install centrifugal pumps,
many applications dictate the need for PD pumps. Because of their
mechanical design and ability to create flow from a pressure input,
PD pumps provide a high efficiency under most conditions, thus
reducing energy use and operation costs.
Choosing centrifugal versus positive displacement

These two main pump styles respond very differently to various
operating conditions, so it is essential to evaluate the requirements
of a process prior to choosing an appropriate pump. Table 1 illustrates the mechanical differences between these pumps, as well
as the effects of pressure, viscosity and inlet conditions on flowrate
and pump efficiency.
Range of operation
Pump styles range far beyond simply PD and centrifugal pumps.
PD pumps encompass many specific styles, including a variety of
reciprocating, rotary and blow-cover pumps. Likewise, centrifugal
pumps encompass radial, mixed, and axial flow styles, which all
Pump Comparison Chart
Centrifugal
Pump
Positive displacement
pump
The pump captures

confined amounts of
liquid and transfers
Mechanics
them from the suction
to discharge port.
Flow is created and
pressure results
Flow varies with
Flow is constant with
Performance
changing pressure
changing pressure
Efficiency increases with Efficiency increases with
Viscosity
increasing viscosity
increasing viscosity
Efficiency peaks at the
best-of-efficiency point.
Efficiency increases
Efficiency
At higher or
with increasing pressure
lower pressures,
efficiency decreases
Liquid must be in the
Negative pressure is
pump to create a presInlet
created at the inlet port.
sure differential. A dry
conditions
A dry pump will prime
pump will not prime on
on its own
its own
The pump imparts a
velocity to the liquid,
resulting in a pressure
at the outlet.
Pressure is created
and flow results
29 CHE 11-07.indd 29

$BQBDJUZ HBMNJO

$FOUSJGVHBMNVMUJTUBHF
.FUFSJOHmQMVOHFS
4DSFX
.FUFSJOHmEJBQISBHN
(FBS
%JSFDUBDUJOHTUFBN
.VMUJDZMJOEFS
"YJBMGMPX
$FOUSJGVHBMEPVCMFTVDUJPO
3FHFOFSBUJWF
$FOUSJGVHBMTJOHMFTUBHF TJOHMFTVDUJPO
Adapted from Perrys Chemical Engineers Handbook
PUMP Specifications
Based on the application in which a pump will be used, the pump
type, and service and operating conditions, the specifications of a
pump can be determined.
Casting connection: Volute casing efficiently converts velocity energy impacted to the liquid from the impeller into pressure energy.
A casing with guide vanes reduce loses and improve efficiency
over a wide range of capacities, and are best for multistage highhead pumps
Impeller details: Closed-type impellers are most efficient. Opentype impellers are best for viscous liquids, liquids containing solid
matter, and general purposes
Sealings: Rotating shafts must have proper sealing methods to
prevent leakage without affecting process efficiency negatively.
Seals can be grouped into the categories of noncontacting seals
and mechanical face seals. Noncontacting seals are often used
for gas service in high-speed rotating equipment. Mechanical face
seals provide excellent sealing for high leakage protection
Bearings: Factors to take into consideration while choosing a
bearing type include shaft-speed range, maximum tolerable shaft
misalignment, critical-speed analysis, loading of compressor
impellers, and more. Bearing styles include: cylindrical bore; cylindrical bore with dammed groove; lemon bore; three lobe; offset
halves; tilting pad; plain washer; and taper land
Materials: Pump material is often stainless steel. Material should
be chosen to reduce costs and maintain personnel safety while
avoiding materials that will react with the process liquid to create
corrosion, erosion or liquid contamination
References
1. Perrys Chemical Engineers Handbook, 7th ed. New York: McGraw

Hill, 1997.
2. Petersen, J. and Jacoby, Rodger. Selecting a Positive Displacement Pump,
Chem. Eng. August 2007, pp. 4246.
10/29/07 5:10:14 PM
CE Community
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30 CHE 11-07.indd 30
10/29/07 5:13:28 PM
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a judgment of the traps condition independent of the
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amount and valuate steam loss, thereby enabling
expense allocation to ROI guidelines.
The operator needs only to place the probe
against the trap for 15 secondsthe TM5 portable
data collection and measurement instrument
performs the analysis automatically. It compares the
measurements against empirical
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31 CHE 11-07.indd 31
10/25/07 6:26:34 PM
People
WHOS WHO
Mahmood
Zant
Axel Johnson Inc. (Fort Lauderdale,

Fla.) names Zain Mahmood president
and CEO of Parkson Corp.
McDonald
Case
Johnson Controls, Inc. (Milwaukee,

Wis.) appoints Stephen A. Roell CEO.
Clarient Masterbatches (Holden,

Mass.) elects Kirk Jacobs business director of Additive Masterbatches.
Danny McDonald becomes vicepresident of North American sales for

Lenze-AC Technology (Uxbridge,
Mass.).
Stephen R. Brand is appointed senior

vice-president of technology at ConocoPhillips (Houston, Tex.).
Lurgi AG (Frankfurt/Main, Germany) names Francois Venet vice

chairman of the executive board.
Hugh Hiigel joins Eclipse, Inc.

(Rockford, Ill.) as corporate services
product manager.
Thomas Zant is appointed president

of Midland Manufacturing (Skokie,
Ill.)
Aschenbroich
Jeffrey Case is named Automotive

Technologies Group director of sales
and marketing by PCB (Depew, N.Y.).
Saint-Gobain Corp. (Valley Forge,
Pa.) elects Jacques Aschenbroich
president and CEO.
SensorLogic (Dallas, Tex.) names Larry
Pereira vice-president of marketing.
Fred McNeil becomes vice president
of business development for Silecs,
Inc. (Mountain View, Calif.).
n
Kate Torzewski
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32
32 CHE 11-07.indd 32
10/25/07 7:43:02 PM
Spectronics
November
Torrey Pines Scientific
KD Scientific
Moderate sample
temperatures with this unit
The EcoTherm Model IC35 Series chilling/heating heavy-duty
dry baths (photo) are fully programmable and can store five programs
in memory with ten steps per program for instant recall and use.
Each program can be made to repeat
automatically from 1 to 99 times. The
IC35 series, with a temperature range
of 10 to 100C, and the IC35XT, with
a temperature range of 20 to 100C,
can freeze, chill or heat samples. A variety of sample blocks are available,
which can hold 0.5 to 50-ml centrifuge
tubes, test tubes, vials, assay plates
and round-bottom flasks. These units
measure 21.6-cm wide, 24.5-cm deep
and 10.2-cm tall. Torrey Pines Scientific, San Marcos, Calif.
Clean filters without downtime
with this duplex basket strainer
Removing particulate matter from
pipeline system flow, the Model 50
Duplex Basket Strainer (photo) protects valves, instrumentation and
meters in large-scale, high-flowrate
systems. This unit has two strainer
basket chambers linked by a pair of
synchronized butterfly valves. This
design allows flow to be diverted from
Eaton Filtration
one chamber to the other for basket

cleaning without shutting off flow, allowing a straight flow path that keeps
startup pressure drops low, even in
high-flowrate applications. The basket
design incorporates a larger screening
area by the use of pleating in the perforated sheet of the strainer, increasing the screening area while maintaining a small unit size. Flow enters
the basket from the side, maintaining
a straight flow pattern that further
reduces the initial pressure drop and
extends time between filter cleaning.
Eaton Filtration, LLC, Elizabeth,
N.J.
Detect leaks from
up to 30 feet away
With a micro discharge light (MDL)
ultraviolet lamp, the Maxima ML3500 Series (photo) allows plant tech-

32D1-12 CHE 11-07.indd 1
nicians to quickly identify small refrigerant and industrial-fluid leaks.

According to this company, the use of
MDL technology makes the ML-3500
Series up to 10 times more powerful
than the UV-A output of conventional
high-intensity discharge lamps. The
Maxima ML-3500S can be used with
fluorescent dyes to detect leaks in lubrication, fuel, ATF, power steering,
coolant, hydraulic and air conditioning/refrigeration systems. With an
inspection range of up to 30 ft and
functionability in sunlight, this unit
can be used in almost any application.
The models are available in 120-, 230-,
240- and 100-V versions. A battery-operated unit is available as well, which
includes a 12-V, 7-A/h rechargeable
battery that will power the lamp for
two full hours. Spectronics Corp.,
Westbury, N.Y.
32D-
10/26/07 1:10:53 PM
New Products
Stafford Manufacturing
Exair
Stop spills
at the first drop
With as little as three drops of liquid, the OS-250 (photo, p. 32D-1) will
react to a spill. This unit consists of
a moisture-sensing mat made from a
material that senses spills, which is
connected by a cable to a control unit.
When liquid is detected on the sensing
mat, the OS-250 controller sounds an
audible alarm, flashes an LED light
and turns off the power of any device
that is connected to the single-outlet,
solid-state power controller. This unit
is supplied with the controller and
four reusable 30 by 30-cm mats that
can be cut down to any shape or size.
KD Scientific, Holliston, Mass.
BS&B
Pressure Safety
Management
Convert plain hubs

into integral clamps
For the conversion of plain hubs on
drive components into integral nonmarring clamps (photo), this firm offers services that promise a more secure fit, prevention of shaft damage,
easier repositioning and greater vibration resistance. This service converts a
plain hub into an integral non-marring
clamp that can be bored to size and
finished with or without a keyway. The
Accu-Clamp feature, which is the integral clamp, retains the integrity of the
hub and has a self-centering clamping
collar that is secured with two socketcap screws. Stafford Manufacturing
Corp., North Reading, Mass.
Dry a variety of materials

with this unit
Producing a 360-deg airstream, the
Super Air Wipe (photo) is used to blow
off, dry, clean or cool the material passing through its center. It features a
split design, allowing it to be clamped
around continuous equipment, such
as pipe, hose, cable, wire and any extruded shapes. This unit functions by
pulling in high volumes of surrounding
room air, then ejecting compressed air
through a thin slotted nozzle. Super
Air Wipes are available in diameters
of , 1, 2, 3 and 4 in. Suggested applications for this equipment include:
wiping wire; drying inks; paint and
screen printing; cooling hot extruded
shapes; and blowoff of water, plating,
coatings and dust. Exair Corp., Cincinnati, Ohio
For pumping solvents, this unit

gives precise measurements
The IDS2000 Industrial Dispenser is
constructed of a valveless-ceramicpiston pump direct-coupled to a precision stepper motor. This unit is designed to dispense solvents in precise
amounts for applications in production and process environments. Capable of dispensing amounts from 2
L to 7 mL, the IDS2000 is ideal for
pumping solvents, lubricants, cleaning agents, flux and adhesives. The
unit now comes with the new Quick
Run Module, an integrally mounted
software that provides users with a
ready-to-use interface. The Quick Run
Module accepts either a foot switch or
an external relay to activate dispensing. Booth 1809 Fluid Metering,
Inc., Syosset, N.Y.
Trap pressure and dust from

high-temperature explosions
To protect powder and bulk-solid process plants and personnel from explosions and flames, the IQR system
(photo) traps dust within its mesh
lining and absorbs heat from flames
and hot gases. The mesh interrupts
the explosion in mid-stream while absorbing the pressure waves and dust
that would normally be ejected by extremely hot and powerful vented explosions. Once the explosion has been
contained and quenched, the IQR
system reduces it to harmless water
vapor and traces of smoke. The system
lowers temperatures down to 100C
followed by a rapid cool down made
possible by its large surface area. Designed for indoor use, the system is
ideal for applications where the impact of a vented explosion should be
32D-
32D1-12 CHE 11-07.indd 2
10/26/07 1:11:32 PM
Increasing your plants efficiency

requires more than changing a few light bulbs.
Fisher-Klosterman XQ Series cyclone dust collectors offer the highest
possible particle removal rates. Many people believe that cyclones are limited to
low efficiency applications, however, at FKI we take cyclone design very seriously.
Our vast experience and scientific knowledge of cyclone design enables us to achieve
extremely high collection efficiencies that in many applications can eliminate the
necessity of final filtration devices. Our sophisticated computer modeling allows us to
offer guaranteed performance when provided with complete operating information.
Another bright idea from Fisher-Klosterman.
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.
32D-3 CHE 11-07.indd 3
10/15/07 12:07:26 PM
Roto-Disc
New Products
avoided for safety or space issues.
BS&B Pressure Safety Management,
LLC, Tulsa, Okla.
This interlock control system
promises a tight seal
This company now offers an interlock
control system (photo) for its inflatable
seal Roto-Flate valve. It creates a hard
link between inflation of the seal and
rotation of the valve. With just one signal, the system allows users to open
or close the valve. This makes control
of the Roto-Flate as easy as a using a
simple quarter-turn valve while maintaining the high performance provided
by the two-stage sealing system. The
Roto-Flate and interlock control system are ideal for pressure- or vacuumprocessing environments that require
bubble-tight sealing, as the inflatable
bladder provides long service life in
conditions where sliding contact seals
would normally fail. The manufacturer recommends applications including filling reactors, vacuum dryer
discharge, or as a shut-off or isolation
valve in dense-phase pneumatic conveying systems. Inlet-port sizes are
available from 3 to 24 in. Roto-Disc
Co., Milford, Ohio
32D1-12 CHE 11-07.indd 4
This media converter extends the

distance of existing networks
The IMC-101G, a new industrialgrade gigabit media converter, offers media conversion between a
10/100/1000BaseT(X) connection and
1000BaseSX/LHX/ZX, allowing users
to extend the distance between copper-based connections with fiber optic
cables. With the ability to extend
transmission distance up to 80 km
and broaden bandwidth up to 1000
Mbps, the IMC-101G provides an economical way to extend the distance
of existing networks for remote management. Each converter comes with
the Link Fault Pass-Through feature,
which allows users to efficiently troubleshoot broken links. The IMC-101G
has a relay output-warning alarm to
prevent damage and loss, support for
redundant power inputs, and IP30rated casing. Moxa Technologies,
Inc., Brea, Calif.
Measure moisture, solids and

ash at once with this analyzer
The MAX 5000 analyzer, created
for dry-ash testing, boasts shorter
throughput time than traditional testing methods, according to the maufacturer. Its results are more accurate
as well, since the analyzer is self-contained and eliminate the risk of mishandling. With the ability to test samples at temperatures of up to 600C in
a small footprint, the analyzer eliminates the need for bulky furnaces. The
option to perform a linked test allows
users to measure moisture, solids, and
ash in samples ranging in weight from
0.2 to 100-g in one procedure. The accompanying software simplifies testing and calculations with the capability to perform statistical and graphical
analyses and save data in high-capacity test result storage. Arizona Instrument LLC, Tempe Ariz.
This safety device limits pressure
and temperature
This specialist in gas technology now
offers the only safety device for a
maximum pressure of 17 bar, satisfying the regulations of EN730 for hydrogen and methane. According to the
manufacturer, many other products
only operate up to a pressure of 10 bar,
making them unusable for certain applications, such as flame spraying. The
unit, which measures 48 mm in dia.
by 101 mm in length, can be installed
directly in the gas line at the tapping
point. The unit provides a flame arrestor that prevents flames from flashing
over the gas tapping point to the gas
supply. Additionally, it has a temperature-controlled cut-off valve which
automatically stops the flow of gas
when the temperature exceeds 105C.
Witt-Gasetechnik GmbH & Co KG,
Witten, Germany
10/29/07 2:07:05 PM
IN CORZAN
CPVC WE TRUST
Is corrosion eating your bottom line?

Choose Corzan CPVC for an industrial piping
solution that offers you more chemical and
financial strength than metal.
For years, Corzan CPVC has demonstrated superior
resistance to many of the chemicals that aggressively
corrode metals. In addition, Corzan CPVC is pressure
rated for operation at temperatures up to 200F (93C).
One of the key advantages of Corzan

CPVC is its excellent resistance to a broad range of
corrosive environments. By replacing metallic systems
with Corzan CPVC, engineers can extend the service
life and reduce maintenance, while minimizing process
life-cycle costs.
For a stronger piping system and stronger profits, trust
Corzan CPVC. We offer superior corrosion resistance,
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32D-5 CHE 11-07.indd 5
5/23/07 2:22:14 PM
10/15/07 12:16:11 PM
Spectroline
New Products
Check for leaks without
equipment disassembly
The CB-1000 Cobra and CB-1036
Cobra-Plus Series of multi-purpose
borescopes (photo) feature a UV and a
white-light LED in each unit that allow
users to inspect and check for leaks in
components without disassembly. The
UV LED is designed to detect refrigerant leaks, fluid leaks and surface
flaws, while the white light LED is
best suited for component inspection.
For most standard inspections, the
Cobra features a 24-in. shaft length.
Designed for inspections that require
extra reach, the Cobra-Plus has a 10mm, 36-in. shaft. Both scopes include
a clip-on inspection mirror for checking flaws that are hidden from view.
Spectroline, Westbury, N.Y.
This gas analyzer provides accurate moisture measurement
Capable of measuring in levels of parts-
per-trillion, the
HALO+ mini-cavity ring-down spectroscopic analyzer provides accuracy, speed, and
repeatability at a lower cost
than other analyzers. Industries that require high purity, includ
ing semiconductor fabrication, laboratory calibration and industrial
process control, will benefit from
the ability of the HALO+ to analyze
gases at ultra-low levels. Particular
processes that are well-suited for the
analyzers high accuracy, speed and
repeatability are continuous quality
control of fixed-bulk gas, portable
mobile-analytical carts, process-tool
monitoring and cylinder quality control of air separation and gas. As this
unit is based on the Beer-Lambert
law, it does not require frequent calibration. Tiger Optics, LLC, Warrington, Pa.
These controllers are suitable for

food-and-beverage applications
This firm has expanded its ArmorStart product line to include
IP69K/NEMA 4X rated variants of
its Bulletin 280/281.283 and 284 distributed motor controllers. The new
additions will allow users in food-andbeverage applications to benefit from
the lower installation costs, reduced
engineering times and ease of maintenance, says the firm. ArmorStart is an
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32D-
32D1-12 CHE 11-07.indd 6
10/26/07 1:12:59 PM
Pointwise
integrated, pre-engineered enclosedmotor controller designed for quick

and easy installation. Its pre-tested,
quick-connect wiring assembly minimizes cabling, cuts labor costs and
helps reduce wiring problems. Installation times can be reduced by up to
30%, says the manufacturer. Together
with a washdown rating of 1,000 psi,
the new NEMA 4X rated versions are
resistant to caustic cleaning agents.
The enclosures and the use of stainless
steel on all exposed metalwork makes

them extremely suitable for hygieniccontrolled environments. Rockwell
Automation, Ltd., Milton Keynes, U.K.
Generate computational fluid
drawing easily and with flexibility
With a flat, intuitive graphical interface, this next-generation meshing
software (photo) reduces the time
needed to generate high-quality CFD
(computational-fluid dynamics) and

allows users to generate grids quickly
and easily. This firm has developed
Pointwise to streamline users gridgeneration experience based on a
new code foundation on which they
can easily implement new features
in response to the changing needs of
clients. The program was designed to
automate as much work as possible to
reduce the time of grid design while
still giving users the flexibility to control the job as much as possible. In
addition to simplifying the meshing
process, Pointwise introduces unified
geometric-curve and grid-curve drawing, as well as simultaneous transformation of CAD geometry and grid.
Pointwise, Fort Worth, Tex.
A new version of this condition
manager is now available
InFusion Condition Manager version
2.2 collects and analyzes realtime di-
32D1-12 CHE 11-07.indd 7
10/26/07 1:13:35 PM
New Products
agnostics from plant production assets, drives the appropriate actions
and now, also shares that information with plant databases and HMIs.
Whereas alternative condition monitoring solutions tend to focus on basic
monitoring of field devices and/or
rotating equipment, InFusion Condition Monitor collects, aggregates and
analyzes realtime data from the full
array of plant-production assets, including sensors and actuators, pumps,
motors, compressors, turbines, dryers and heat exchangers and even
entire process units, says the firm.
Thanks to Version 2.2 enhancements,
the information can now be easily displayed on plant-process-control and
engineering HMI workstations. Invensys Plc., London, U.K.
For flux membrane bioreactors,
this filter is the largest
This company has added a 1500-m2
filtration system (photo)

to its line of Puron membrane bioreactor (MBR)
models. This new design
features greater packing density and lower
energy costs for aeration
and simplified installation, says the manufacturer. The Puron MBR
modules are available
with membrane areas of
30, 235, 500, or 1500 m2.
The newest and largest
design is specifically intended for large-scale
MBR projects, and features an optimized permeate-extraction manifold and air-supply lines
that reduce the number of piping
connections needed during installation. Additionally, the central aeration
system and bottom header have been
redesigned to reduce the flowrate during air scouring, reducing air usage by
Koch Membrane Systems
up to 20% over the previous design. To

prevent the buildup of fibrous materials, this system uses a single header
with hollow fibers that are fixed only
at the bottom, allowing the upper ends
to float freely. Koch Membrane Systems, Wilmington, Mass.
Tru
En
Durc
Pum
32D-
32D1-12 CHE 11-07.indd 8
10/26/07 1:14:10 PM
Detect low levels of gas

with this analyzer
This company now offers the SenseLine ELDS OPGD, an open path gas
detection system, which features enhanced laser-diode-spectroscopy technology. OPGD requires fewer units to
establish a detection zone, compared
to existing point-type gas detectors,
and transmitters and receivers can
be spaced from 5 to 200 m apart.
When low levels of a hazardous gas
pass through any part of the laser
line, the system reports the gas leak
early enough to allow the user to take
remedial action. This new system offers many new benefits, including:
high sensitivity, absolute selectivity,
multi-gas detection capabilities for
hazardous gases, remote-electronicfunctional testing, and reduced costs
of installation, maintenance, and field
deployment. Sensient, Inc., Houston, Tex.
This wireless transmitter

communicates corrosion data
In a joint project with Rohrback Cosasco Systems (RCS; Santa Fe Spring,
Calif.), this company has introduced
the Microcor wireless transmitter
for high-speed communication of corrosion-rate data. Coupled with this
firms smart wireless offerings, corrosion information from the Microcor
device can be used in the automation
system where it can be logged, trended
and analyzed. This unit is compatible
with AMS Suite, intelligent-devicemanager software used for device configuration, calibration, documentation
and predictive diagnostics. The device
provides nearly realtime corrosion
rates, which allows operators to detect
a spike in corrosion, control inhibitor injection and correlate with other
process data for root-cause analysis.
Emerson Process Management,
Austin, Tex.
Trusted In Any
Environment
Durco & IDP Magnetic Drive
Pumps From Flowserve
Take accurate position measurements from 240 feet away

Designed for precise level, distance
and position measurement of dry bulk
solids, opaque liquids and slurries,
the SureShot140XP smart laser level
transmitter takes measures from up
to 240 ft away. The device features
a measurement laser as well as an
alignment laser, which allows accurate data to be taken while eliminating false echoes due to beam convergence. The narrow measurement laser
can be directed through tight spaces
as small as 3 in. in diameter. Constructed in small and compact housing, this transmitter requires no calibration or configuration for easy setup
and configuration. Even in the presence of outside noise, such as chemical
vapors, dust, smoke or agitator blades,
this transmitter will produce accurate
results. Standard housing is powdercoated aluminum with optional stainless steel. The explosion-proof assem-
Safety assurance.
Environmental impact.
Process downtime.
No matter what drives your decision, Flowserve
offers the versatile and reliable magnetic drive pumps
to meet your needs. Just what you would expect from
the leading name in chemical process pumps.
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drive pumps
When zero leakage is the only acceptable outcome,
plant managers rely on Flowserve to keep their
plants running safely and profitably.
Ask your Flowserve representative or

visit http://sealless.flowserve.com
for more information.
32D1-12 CHE 11-07.indd 9
10/26/07 1:14:54 PM
Malvern Instruments
New Products
bly with a screw-on glass cover make
this unit easy to use and appropriate
for hazardous locations. K-TEK
Corp., Prairieville, La.
Create nanodispersions of poorly
soluble organic materials
Iota Nanosolutions (Liverpool, U.K),
which specializes in the formation of
nanodispersions of poorly soluble organic materials, has been using the
Zetasizer Nano particle characterization system (photo) for the processes of
sample optimization and quality control processes. This technology enables
the conversion of hydrophobic organic
materials into dry solids, allowing solids can then be added to water to form
colloidally stable nanodispersions
of the actives. The Zetasizer Nano is
used to measure the particle size and
stability of these dispersions, and has
been used to convert over 150 different
organic compounds used in cosmet-
ics, pharmaceuticals, consumer

products, agrochemicals, inks,
and coatings. The Zetasizer
Nano performs nanodispersion
analysis by testing nanoparticles in solution, rather than
after preparation onto a surface.
Booth Malvern Instruments.,
Worchestershire, UK
For high-temperature corrosion
resistance, use these quenchants
The UCON Ultraquench Plus Series
quenchants, this companys next generation of products for the heat-treating industry, are polymer-based products that provide superior corrosion
protection and bacteria resistance.
These non-flammable aqueous polymer solutions contain a nitrite-free
corrosion inhibitor packages for the
protection of metals during high-temperature manufacturing. This makes
these quenchants ideal for processing
medium-high carbon steel and alloyed

steel of most grades, including 300
and 400 Series stainless steel. The
Ultraquench Plus Series cuts down on
emissions during the manufacturing
process and does not produce smoke,
soot, or any other waste products related to oxidation. The Dow Chemical Company, Midland, Mich.
This data logger allows
users to view data graphically
The Fluke 289 True-rms industrial logging multimeter with TrendCapture
SPEC IT AND
FORGET IT.
Check-All Valve is your
one-stop supplier for the
check valves you need in the
materials you require. Better
yet, every valve includes the
experience, engineering, and
application know-how you need
for spec-it-and-forget-it reliability.
After all, you have better things to
do, and check valves are all we do.
Call us at 515-224-2301 or
e-mail us at sales@checkall.com.
Since 1958
West Des Moines, Iowa USA
www.checkall.com
32D-10
32D1-12 CHE 11-07.indd 10
10/26/07 1:15:47 PM
Panasonic
logs data and presents it graphically

on screen in order to solve complex
problems in electronics, plant automation, power distribution and electromechanical equipment. The unit has a
logging function with expanded memory to store up to 10,000 readings for
unattended monitoring of signals over
time. Multiple logging sessions can be
saved to the unit and reviewed graphically with the TrendCapture capability before downloading to a computer
is necessary. The optional FlukeView
software allows users to document,
store and analyze individual readings
Drops and vibrations will not

affect these sturdy laptops
Two rugged, mobile computers manufactured by this company have recently become available. The Toughbook computers (photo), UL 1604
certified for use in Class 1, Division
2 hazardous locations, are designed
for spark-free use in potentially explosive environments, particularly in
the oil-and-gas, petrochemical, and
aviation industries. The Toughbook
19 is a convertible tablet PC, while
the Toughbook 30 is a clamshell notebook. MIL-STD-810F tested to deter-
mine the most severe conditions that

these computers can face, the Toughbook notebooks are built to withstand
drops, shocks, vibration and extreme
temperature. These durable notebooks
have magnesium alloy cases, sealed
keyboard and ports for dust and water
resistance, flexible internal connectors
and shock-mounted hard drives and
LCDs. With a battery life of six hours
and a brightness of 550 candelas/m2
LCD screen, the UL 1604 series is an
excellent and practical alternative to
stationary computers. Panasonic,
Secaucus, N.J.
A plastic shutoff valve
that closes automatically
This firm has introduced a 1/2-in. size
palm- or foot-operated shutoff valve
with no metals or external fasteners
for high-purity or corrosive environments. These compact valves are designed for liquid service to 150 psi. The
ìi}o
PROTECT PUMPS
or a series of measurements,
and
then convert them
into professionallooking
reports.
Fluke Corp., Everett, Wash.
edlinks.che.
com/6901-352
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32D1-12 CHE 11-07.indd 11
32D-11
10/26/07 1:18:47 PM
New Products
Thermo Fisher Scientific
normally closed design has a spring

return, and will automatically close
fail-safe when hand or foot force is removed. The MFR is offered in Grade 1
Type 1 PVC or natural polypropylene.
Plast-O-Matic Valves. Inc., Cedar
Grove, N.J.
This extension software
integrates full instrument control
The Accela High Speed LC system
now has add-on instrument control
software, the Atlas Chromatography
Data System (CDS; photo), providing
integrated instrument control, digital
data acquisition, chromatography data
processing and reporting. This extension kit integrates full instrument
control and chromatography data
handling for the Accela high-speed
pump, autosampler and PDA detector. Designed as a multi-user, multiinstrument data system, the Atlas
CDS enables remote-network access
to any Accela to fully collect, secure

and protect data. The highly scaleable
client-server environment for laboratory LAN and WAN networks is ideal
in pharmaceutical drug development,
discovery, QA and QC laboratories,
academics, and food and beverage industries. Thermo Fisher Scientific,
San Jose, Calif.
Recycle cleaning fluids
with this sealless pump
Hydra-Cell sealless pumps are effective for cleaning applications and are
especially suited for handling recycled
fluids containing particulates. These
high-pressure, positive-displacement
pumps incorporate hydraulically balanced diaphragms and have no rotating seals, which can be destroyed by
particles as small as 25 m. The pump
drive shaft is rigidly held in the pump
housing by a large, tapered roller bearing that is immersed in a lubrication-oil
bath. A fixed cam translates rotary motion into linear motion to the hydraulic
cells, which displace diaphragms, so
stress is eliminated. The pumps cover
flowrates from 0.4 to 128 L/min and
pressures up to 172 bar. Wanner Engineering, Inc., Minneapolis, Minn.
Kate Torzewski
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32D-12

#%7EB(OUSE!DINDD
32D1-12 CHE 11-07.indd 12
!-
10/26/07 1:19:29 PM
November
Drger
Safety
Your view is not

obstructed by this mask
The FPS 7000 breathing protection
mask (photo) features a large visor,
which provides the user with a large
and wide field of view even when
looking down. Carefully designed air
circulation within the mask protects
against condensation on the viewing glass. Three mask body sizes
and four internal mask sizes are
available to ensure a perfect fit.
A newly developed communication system, the FPS-COM, optimally adapts to the construction
and design of the full breathing
protection mask. Drger Safety
AG & Co. KGaA, Lbeck, Germany
JP Pumps
Determine water content with

this automatic titrator
The 870 KF Titrino plus (photo) is this
firms new Karl Fischer titrator for
volumetric water determinations. The
instrument can be used to reliably and
accurately determine water contents
from a few parts per million (ppm) up
to 100% in solid, liquid and gaseous
samples. With an operating interface
designed for routine users, the unit is
ideal for everyday determinations. A
compact USB printer is available as an
option. Deutsche Metrohm GmbH &
Co. KG, Filderstadt, Germany
When space is limited,
consider this centrifugal pump
The Combiflex vertical single-stage
centrifugal pump (photo) is especially suitable for liquid-transfer applications where space is limited. The
pumps offer a maximum capacity of
1,500 m3/h, heads up to 100 m and
a maximum working pressure of 10
bar. Several versions are available to
match the application. For example,
the K1 and K3 Models with spacesaving coupling have the advantage
of the top pull-out principle, whereas
Deutsche Metrohm
the K2 and K4 versions have a shorter

construction with standard coupling.
A key feature of the Combiflex pump
is the suction-bend design, which is
available in eight different mounting
positions as well as a very flat design
with low-flow resistance. JP Pumps
Ltd., Crawley, U.K.
Angle-seat globe valves now
come with flange connections
The GEM 550 with pneumatic stainless-steel actuator and the GEM

32i-1-11 CHE 11-07.indd 1
GEM Gebr. Mller Apperatebau
507 manual valve are available with

flange connections in nominal sizes
DN 15 to 50. The new flanged bodies (photo) are made of 1.4408 cast
stainless steel. Flanges are PN16
and PN25 to EN 1092 form B, length
EN 558-1 Series 1. Flanges to ANSI
B 16.5 are also available. These new
connection types extend the companys angle-seat globe-valve product
range. GEM Gebr. Mller Apperatebau GmbH & Co. KG, IngelfingenCriesbach, Germany
32I-
10/26/07 1:52:25 PM
New Products
Easy to install lining protects
against spills in tank rooms
This firms new tank-room lining
(photo) is designed to seal drip
pans and rooms used to store
water polluting liquids. The individual sheets are factory welded
to be leak-tight. The lining is
then installed in the tank room
and fitted to the wall via aluminum rails. Installation does
not require extensive preparation work in the tank room. An Afriso-Euro-Index
optional oil-water alarm unit can be lecular pumps or leak detecinstalled in the room, which gener- tors via the RS 485 interface. A
ates a visual and audible alarm sig- Profibus or DeviceNet interface
nal in case of internal damage. The can be provided via a fieldbus
Pfeiffer Vacuum
alarms can also detect liquids from converter. Pfeiffer Vacuum
the outside, such as may result from GmbH, Asslar, Germany
sistance to metals
flooding. Afriso-Euro-Index GmbH, edlinks.che.com/6901-396
(metal plating and
Phoenix Contact
Gglingen, Germany
metal-recovery proedlinks.che.com/6901-394
A new control system
cesses). Emerson Process Managefor operating boilers
ment, St. Louis, Mo.
Convert thermocouple data into
All new incoming shell boiler or- edlinks.che.com/6901-398
420 mA signals with this module
ders from this firm will be equipped
The loop-powered temperature mea- with new boiler and system controls. Motor controllers that suit
suring transducer MCR-SL-PT100- A graphic TFT color monitor with food and beverage applications
UI-LP (photo) converts measured val- a touch-screen interface is used for This firm has expanded its Arues from Pt 100 sensors (IEC 751/EN displays and for boiler operation. An morStart product line to include
60751) into standardized 420-mA industrially proven stored-program IP69K/NEMA 4X rated variants of
signals. Electrically isolated mod- control provides a reliable basis for its Bulletin 280/281.283 and 284 disules convert measurement ranges mapping the complex regulating, con- tributed motor controllers. The new
from 150 to 300C. Pt 100 sensors trol and protection functions of the additions will allow users in food-andcan be attached at the input using firms boiler systems. The software beverage applications to benefit from
two-, three- or four-wire connections. modules were developed in house and the lower installation costs, reduced
On the output, the transducer is oper- are configured on an order-specific engineering times and ease of mainteated in a 420-mA signal loop, which basis. Loos Deutschland GmbH, nance, says the firm. ArmorStart is an
delivers the necessary power sup- Gunzenhausen, Germany
integrated, pre-engineered enclosedply to the module at the same time. edlinks.che.com/6901-397
motor controller designed for quick
Phoenix Contact, GmbH & Co. KG,
and easy installation. Its pre-tested,
Blomberg, Germany
Customized electrolytes keep
quick-connect wiring assembly miniedlinks.che.com/6901-395
reference electrodes healthy
mizes cabling, cuts labor costs and
The Rosemount Analytical PERpH-X helps reduce wiring problems. InstalTwo types of vacuum gauges
sensor family is customized to handle lation times can be reduced by up to
are combined into one unit
different processes by using different 30%, says the manufacturer. Together
The new MPT 100 transmitter (photo) reference electrolytes. Six different with a washdown rating of 1,000 psi,
expands this firms portfolio of Digi- refill solution kits are available, each the new NEMA 4X rated versions are
Line vacuum instruments. The device using a specific chemistry formulated resistant to caustic cleaning agents.
combines a Pirani and a cold-cathode to extend the life of the reference The enclosures and the use of stainless
sensor, which enables it to cover the electrode in the targeted applica- steel on all exposed metalwork makes
broad measurement range from 5 X tion. These include: operation at high them extremely suitable for hygienic109 to 1,000 mbar, and also is insen- temperature (to 145C); resistance to controlled environments. Rockwell
sitive to gas inrush. The two sensors biofilm (for municipal wastewater); Automation, Ltd., Milton Keynes, U.K.
are matched to each other in order to resistance to poisoning (Kraft paper edlinks.che.com/6901-399
eliminate the possibility of contami- mills, desulfurization); resistance to
nation, a feature that makes the MPT oil (hydrodesulfurization processes, This PET crystallizer
100 suitable for coating systems, as poultry processing); resistance to is energy efficient
well. The device can be combined with scaling, limestone scrubbers, lime- Developed and manufactured in cothe firms backing pumps, turbo-mo- slaking in sugar processing); and re- operation with Lanco GmbH (Hanau,
32I-
32i-1-11 CHE 11-07.indd 2
10/26/07 1:53:08 PM
32i-3 CHE 11-07.indd 3
10/15/07 12:32:31 PM
FDM
New Products
Germany), these polyethylene
terephthalate (PET) crystallizers
(photo) are designed as solid-bed
units that transform PET material
from the amorphous to the crystalline state. As a result, agglomeration of the material during the
drying process is avoided, material handling becomes easier, and
the processing of PET and PLA is
simplified, says the firm. The
process recovers 80% of the
processing heat, which can
be used for the crystallization. Operating costs
for the production of PET
can be reduced by up to
100 W/kg/h says the firm.
FDM GmbH, Knigswinter, Germany
This powerful microwave
dryer takes a big load
The Microwave Vacuum Test Dryer
(photo) has a 200-mm dia. and length
of 2,500 mm, with a large opening for
loading. The unit can be used with different atmospheres and operate with
a rough vacuum of 10 mbar. The microwave power (12 x 800 W, or 9.6 kW)
is continuously adjustable between 15
and 100%. Options include a smoke
detector and an extinguishing system.
Applications include drying of wood,
ceramics, chemicals, food, building
materials and fiber-reinforced materials. Linn High Therm GmbH,
Eschenfelden, Germany
A better way to control
batch-crystallization processes
Realtime, non-invasive monitoring of
heat liberation and absorption during a process can revolutionize the
way you optimize your crystallization process and control production to
improve batch-to-batch consistency,
says this firm. The ChemFlux reactor system (photo) measures power,
enthalpy and temperature information to enable accurate determination
of the point of nucleation, the rate of
crystal growth and the reaction end
point. The amount of product can also
be calculated. Powder Systems Ltd.,
Liverpool, U.K.
32I-
Powder Systems
Linn High Therm
A paperless recorder that

thinks like a data logger
This new line of digital data recorder
collects and manages process variable
information to optimize process production and regulatory accountability.
The Foxboro 6100 Data Management
Series incorporates advanced digital
technologies to provide ease of use,
high security and adaptability to a
wide range of production processes, including batch applications. The paperless recorders feature extended input
capability to communicate with up to
32 slave devices, providing up to 176
inputs. The slave devices can be used
for data acquisition for variable process information, including pressure,
flow, temperature and electrochemical
analyses, such as pH and conductivity measurements. The 6100 Series
also supports Electronic Signatures
in accordance wioth FDA 21 CFR part
11 requirements. Invensys Plc.,
London, U.K.
This gas detector also alarms
when the user is in distress
The new Altair 4 is said to be one of
the most rugged four-gas detectors
available. The device measures O2,
H2S, CO and combustible gas simultaneously, and comes with a

triple alarm system, 24-h bump test
check-mark and comprehensive data
logging facility as standard. When
enabled, the optional MotionAlert
man-down alarm with motion detector alerts anyone in the vicinity, if the
user is in distress, with high visibility
LEDs and a piercing audible alarm.
MSA Europe, Berlin, Germany
A new version of this condition
manager is now available
InFusion Condition Manager version
2.2 collects and analyzes realtime diagnostics from plant production assets, drives the appropriate actions
and now, also shares that information with plant databases and HMIs.
Whereas alternative condition monitoring solutions tend to focus on basic
monitoring of field devices and/or
rotating equipment, InFusion Condition Monitor collects, aggregates and
analyzes realtime data from the full
array of plant-production assets, including sensors and actuators, pumps,
motors, compressors, turbines, dryers and heat exchangers and even
entire process units, says the firm.
Thanks to Version 2.2 enhancements,
the information can now be easily displayed on plant process control and
engineering HMI workstations. Invensys Plc., London, U.K.
A tiny GC module
for online monitoring
This firms miniaturized module for
fast gas chromatography (GC) is especially suitable for cost-effective online
32i-1-11 CHE 11-07.indd 4
10/26/07 1:53:49 PM
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
32i-5 CHE 11-07.indd 5
10/15/07 12:21:21 PM
New Products
Michael Smith Engineers,

BS&B
Pressure
Safety
Management
connectBlue
analysis applications, such as in the

utility grid. The first surface-mounted
ANSI/ISA 76.00.02 2002 online GC
module was launched last month at the
ISA Exhibition in Houston, Tex. This
technology platform allows improved
lifetime and reduced costs of GC applications in the energy sector, as well as
for those in industrial processing, mining and environmental, security and
safety, laboratories and quality control.
C2V, Enschede, Netherlands
A venting device that renders powder fires or explosions harmless
The IQR System (photo) is an explosion-venting device designed to protect powder and bulk-solid process
plants and personnel from explosions
and flames. The system provides protection against fire and explosion by
trapping dust within its mesh lining
and absorbing heat from flames and
hot gases. The mesh acts as a heat
sink that interrupts the explosion in
mid-stream while absorbing pressure
waves and dust that would normally
be ejected by extremely hot and powerful-vented explosions. The contained
and quenched explosion from the IQR
System is reduced to harmless water
vapor and traces of smoke. BS&B
Pressure Safety Management, LLC,
Tulsa, Okla.
32I- Chemical Engineering www.che.com November 2007
32i-1-11 CHE 11-07.indd 6
Syrris
Simplify configuration and testing

with this wireless adapter port
By eliminating the need for cables for
connections and external power, the
new USB Serial Port Adapter (photo)
with Bluetooth and Wireless LAN
(WLAN) functionality makes configuration and testing easier for industrial
programmers. The adapter automatically installs itself as a virtual COM
port when connected to the computer.
The installation runs smoothly as the
industrial application programmer
gains full control via the connectBlue
standard AT commands. No additional
software is needed as the Bluetooth
and WLAN stacks are incorporated in
the connectBlue module. connectBlue, Malm, Sweden
Recycle cleaning fluids
with this sealless pump
Hydra-Cell sealless pumps (photo) are
effective for cleaning applications and
are especially suited for handling recycled fluids containing particulates.
These high-pressure, positive-displacement pumps incorporate hydraulically
balanced diaphragms and have no ro-
10/26/07 1:54:39 PM
32i-7 CHE 11-07.indd 7
10/15/07 12:18:48 PM
New Products
Raytek
Plast-O-Matic Valves
APV
tating seals, which can be destroyed by

particles as small as 25 m. The pump
drive shaft is rigidly held in the pump
housing by a large, tapered roller bearing that is immersed in a lubrication-oil
bath. A fixed cam translates rotary motion into linear motion to the hydraulic
cells, which displace diaphragms, so
stress is eliminated. The pumps cover
flowrates from 0.4 to 128 L/min and
pressures up to 172 bar. Michael

Smith Engineers, Woking, U.K.
Another module introduced for
this automated synthesis system
The Orbit parallel chemistry module
(photo, p. 32I-6) is the latest addition to the Atlas family of intelligent
and modular automated-synthesis
60 Samples in 60 Minutes
The New SPECTRO ARCOS High Performance ICP Spectrometer
systems. The Orbit readily fits the

Atlas Hotplate, Hot and Cold Circulator Plate or any regular third-party
equivalent, and allows reactions to be
heated to 280C with reflux, or cooled
to 40C. Available in two different
sizes, Orbit can accommodate up to
six 45-mL test tubes or twelve 10-mL
tubes. Syrris Ltd., Royston, U.K.
The new SPECTRO ARCOS is an extraordinary ICP spectrometer.

A particularly noteworthy characteristic is its extreme speed.
Many measures from sample introduction to readout and
processing of the data ensure that the analytical results are
available faster than ever before. Depending on the application,
up to 60 samples per hour can be analyzed in automatic mode;
more than any other ICP available on the market today.
SPECTRO ARCOS
High Performance ICP Spectrometer
Short fluid paths, automatic flush time control and high speed
readout system for rapid analysis times
extended wavelength range and highest resolution for excellent
sensitivity and precision
Novel, extremely robust generator for absolutely stable plasma conditions
Low maintenance UV system with minimal operating cost
Find out more about the new ICP

performance class for complex
analytical requirements.
www.spectro.com
Tel. +49.2821.892-2102
spectro.info@ametek.com
32I-
32i-1-11 CHE 11-07.indd 8
10/26/07 1:55:52 PM
A plastic shutoff valve that

solids, opaque liquids and slurries, through tight spaces as small as 3 in.
closes automatically
the SureShot140XP smart laser level in diameter. Constructed in small and
This firm has introduced a 1/2-in. size transmitter takes measures from up to compact housing, this transmitter repalm- or foot-operated shutoff valve 240 ft away. The device features a mea- quires no calibration or configuration
(photo, p. 32I-8) with no metals or ex- surement laser as well as an alignment for easy setup and configuration. Even
ternal fasteners for high-purity or cor- laser, which allows accurate data to be in the presence of outside noise, such
rosive environments. These compact taken while eliminating false echoes as chemical vapors, dust, smoke or
valves are designed for liquid service due to beam convergence. The narrow agitator blades, this transmitter will
07_TSC-e_A:06_Service-d 08.05.2007 16:16 Uhr Seite 1
to 150 psi. The normally closed design measurement laser can be directed produce accurate results. Standard
has a spring return, and will automatically close fail-safe when hand or We l c o m e t o o u r s e a l i n g w o r l d
foot force is removed. The MFR is of- w w w . e a g l e b u r g m a n n . c o m
fered in Grade 1 Type 1 PVC or natural polypropylene. Plast-O-Matic
Valves. Inc., Cedar Grove, N.J.
Take accurate position measurements from 240 feet away

Designed for precise level, distance
and position measurement of dry bulk
env
ironment.
cl
an
Total expenditure for

mechanical seals cut by up
to 45%, the number of
repairs by 55%, costs for
bad actors down by as
much as 40% and, on top of
all that, repair times halved!
Those are the results of our
200 service contracts around
the world.
Now it`s up to you ...
TotalSeatCare TM : The comprehensive seal service from
EagleBurgmann.
r
fo
of
This efficient heat exchanger

has a small footprint
The Zephyr plate heat exchanger
(photo, p. 32I-8) is the latest addition
to this firms XL Series. The unit features a large heat-transfer area with
high thermal efficiency, with 400-mm
dia. ports to offer flowrates up to 3,000
m3/h per unit. As a result, fewer Zephyr
heat exchangers in parallel can do the
same heating or cooling job as a large
number of conventional units, says the
firm. Customers can choose between a
wide variety of plate sizes and configurations that can be tailored to their
specific needs all with a minimal
footprint. APV, Kolding, Denmark
Some convincing
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ro
Just about any process

can use this IR thermometer
The XR infrared (IR) thermometer
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to optimize continuous temperature
monitoring in a broad range of manufacturing processes. The device measures temperatures in the range of 40
to 1,650C and has an RS-485 interface. The user-defined analog output
can be matched to almost any existing
control system a feature that eliminates the need for analog-to-digital
(A/D) conversion or non-standard A/D
input cards, says the firm. Raytek
GmbH, Berlin, Germany
Le
ak
Burgmann Industries
GmbH & Co. KG
D-82502 Wolfratshausen
Tel. +49 / 8171 / 23-0
Fax +49 / 8171 / 23 10 95
32i-1-11 CHE 11-07.indd 9
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housing is powder-coated
aluminum with optional
stainless steel. The explosion-proof assembly with a
screw-on glass cover make
this unit easy to use and
appropriate for hazardous
locations. K-TEK, Prairieville, La.
Stop spills
KD Scientific
at the first drop
With as little as three drops of liquid, the OS-250 (photo)
will react to a spill. This unit consists of a moisture-sensing
mat made from a material that senses spills, which is connected by a cable to a control unit. As soon as liquid is detected on the sensing mat, the OS-250 controller will sound
an audible alarm, flashes an LED light and turns off the
power of any device that is connected to the single-outlet,
solid-state power controller. This unit is supplied with the
controller and four reusable 30 by 30-cm mats that can be
cut down to any shape or size. KD Scientific, Holliston,
Mass.
This safety device limits
pressure and temperature
This specialist in gas technology now offers the only safety
device for a maximum pressure of 17 bar, satisfying the
regulations of EN730 for hydrogen and methane. According
to the manufacturer, many other products only operate up
to a pressure of 10 bar, making them unusable for certain
applications, such as flame spraying. The unit, which measures 48 mm in dia. by 101 mm in length, can be installed
directly in the gas line at the tapping point. The unit provides a flame arrestor that prevents flames from flashing
over the gas tapping point to the gas supply. Additionally,
this safety device has a temperature-controlled cut-off
valve which automatically stops the flow of gas when the
temperature exceeds 105C. Witt-Gasetechnik GmbH &
Co KG, Witten, Germany
Clean filters without downtime
with this duplex basket strainer
Removing particulate matter from pipeline system flow, the
Model 50 Duplex Basket Strainer protects valves, instrumentation and meters in large-scale, high-flowrate systems.
This unit has two strainer basket chambers linked by a pair
of synchronized butterfly valves. This design allows flow to
be diverted from one chamber to the other for basket cleaning without shutting off flow, allowing a straight flow path
that keeps startup pressure drops low, even in high-flowrate
applications. The basket design incorporates a larger screening area by the use of pleating in the perforated sheet of
the strainer, increasing the screening area while maintaining a small unit size. Flow enters the basket from the side,
maintaining a straight flow pattern that further reduces
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32i-1-11 CHE 11-07.indd 10
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10/26/07 1:59:37 PM
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10.10.2007
15:58 Uhr
Seit
W W W. G E A J E T. C O M
Through the suction

nozzle, gas or liquid is
drawn in and entrained
by the motive stream.
Jet Pumps
Our jet pumps set standards.
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in water treatment plants,
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Detect leaks from

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With a micro discharge light (MDL) ultraviolet lamp, the
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Create nanodispersions of
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Iota Nanosolutions (Liverpool, U.K), which specializes in
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actives. The Zetasizer Nano is used to measure the particle size and stability of these dispersions, and has been
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in cosmetics, pharmaceuticals, consumer products, agrochemicals, inks, and coatings. The Zetasizer Nano performs
nanodispersion analysis by testing nanoparticles in solution, rather than after preparation onto a surface. Booth
Malvern Instruments., Worchestershire, UK

Gerald Ondrey
chemical reactors, mixing

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Here the mixture
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32I-11
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32i-12 CHE 11-07.indd 12
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33 CHE 11-07.indd 33
10/15/07 12:05:20 PM
Feature
Cover
Story
Report
Going Wireless
Using this technology
to optimize overall
operations offers longterm benefits for the
bottom line
Jeff Becker
Honeywell Process Solutions
s the chemical process industries (CPI) make the transition

from communication protocols
and systems that are cableready to those that are wireless, the
conversation is changing. On the plant
floor and in the executive suite, terms
such as mesh network and interoperability bring new meaning to the manufacturing environment.
But what does it all mean? How can
companies truly begin to decode this
new wireless world and choose which
wireless solution, if any, is the right
one for their operations?
Strategies for prioritizing wireless applications in chemical process
plants include determining where
wired solutions are impractical or cost
prohibitive, identifying applications
that involve high-energy and natural-resource usage, and optimizing
field-worker productivity. And these
decisions must be made with consideration to future applications and technologies that are not yet available.
Consider, for example, the case of an
ethanol-plant tank farm, where large
tanks serve as holding stations for
ethanol to be delivered to distributors.
Although the tanks are ventilated, the
tank farm is an enclosed area and the
ethanol, which is nearly pure-grade alcohol, emanates intense vapors. Since
the vapors always pose the risk of ig34
nition, the tank farm is considered an

explosive environment.
The tank farm operator was planning to install digital transmitters
to monitor tank levels when he hit a
roadblock with the traditional wired
devices. Because the tank farm was
an explosive hazard area, workers
were precluded from using electrical
devices and wiring that werent specifically designed and labeled explosionproof or intrinsically safe.
For regular wiring, the company
could have expected to pay about $25
40/ft. By comparison, explosionproof
or intrinsically safe wiring would cost
about $80100/ft. In this particular
case, installing a series of wireless
transmitters to monitor the tank levels proved a safer, and more affordable, solution.
This example illustrates one of the
obvious benefits of industrial wireless solutions reduced installation
costs. Without any wiring or conduit to
install, the implementation is easier
for vendors, and less expensive and
intrusive for operators.
Applied strategically, the benefits of
industrial wireless extend far beyond
the cost savings of fewer wires to run.
For instance, transmitters such as
those used at the aforementioned tank
farm, add value to the operation because they allow the company to keep
better track of its inventory. Because
34-39 CHE 11-07.indd 34
10/29/07 5:43:52 PM
FIGURE 1. Backbone meshes typically involve powered nodes that communicate

with each other across long distances, connecting various parts of the plant. These
nodes allow thousands of devices to co-exist on a single network infrastructure
the company can more accurately

monitor tank levels, it can streamline
throughput and optimize operations.
These are some of the factors that
CPI companies should consider when
contemplating how wireless can fit
into their facilities. Because wireless
can be a complex enabling technology, it requires careful research before
implementation. However, using this
technology to optimize overall operations as well as reduce wiring costs
can result in longterm benefits that
directly impact a plants bottom line.
A wireless gamut
An industrial wireless solution can

include anything from a network of
transmitters monitoring a single, specific application within a plant, to a
full-scale wireless mesh network deployed across an entire site to handle
multiple applications.
An informal analysis of an existing
customer base for wireless technology reveals some interesting buying
trends. Initially, the typical purchases
were relatively small five transmitters per project, for example. But over
the last four years or so, the average
number of transmitters purchased
at these same sites has steadily increased. In fact, users initial orders
have proven to be a small percentage
of the overall wireless technology they
eventually purchase. In other words,
most companies start small and expand their plants wireless systems.
Another buying trend has emerged
with the recent availability of mesh network solutions. Despite the availability
of this technology, some wireless vendors expected users to introduce wireless into their plants with small projects
aimed at monitoring specific applications and gradually implement a larger
network. Instead, a surprisingly large
number of users are showing initial
interest in the larger networks. Either
way, network choices must be scaleable
to accommodate future requirements.
In the evolution of wireless technology, the first generation of products
was sensor specific and not designed
to cover entire plants, which was reflected in the smaller purchases.
Today, the new generation of products
is more appropriate for wider plant
deployment.
Basically, the main uses for industrial wireless technology can be
grouped into three categories: safety,
reliability and efficiency.
Safety issues. Nothing has a more
profound impact on a manufacturing
facility than a safety incident. The
losses can range from equipment and
materials to products and profits, and
in a worst-case scenario, personnel.
Wireless solutions are most advantageous in hazardous areas that require manual measurements, where
wireless sensors can reduce the need
for workers to physically put themselves in harms way and provide a
safer environment for monitoring
data points. Less wiring also reduces
the potential for a deadly spark. As
well, there are other innovative ways

in which wireless technology can increase plant safety.
In the U. S., for example, regulations
require control rooms to be notified
within ten seconds of a safety shower
being activated. To comply with this
relatively new regulation using conventional technology, a typical CPI
facility would need to rewire dozens of
safety showers. By contrast, a series of
wireless sensors solves the problem at
a significantly lower cost. The addition
of wireless video cameras, triggered
by these sensors, could further allow
safety managers to assess plant operations and take appropriate steps.
Wireless technology also improves
safety through people and asset-tracking capabilities. With various location
technologies, new wireless solutions
can enable managers to track employees on the plant floor. This capability is
crucial in the event of a plant incident
because it allows managers to quickly
account for their people and better coordinate with emergency responders.
This same tracking technology can
be used to monitor the movement of
hazardous equipment and materials,
or even to interlock process steps with
a verification that all personnel are in
the appropriate place.
Equipment reliability. Maintenance
is an expected, and often expensive,
cost item for any process plant because equipment wears down and
pipes corrode.
Yet, the right kind of monitoring
solution can help minimize or prevent the effects of natural wear and
tear, thereby increasing plant uptime.
Wireless technology can be advantageous for plant reliability, especially
as it is applied to three key areas: corrosion monitoring, equipment-health
monitoring and the dutifully named
wireless worker.
To monitor corrosion, companies
typically take measurements at various points throughout a plant, collecting data that can be used determine
the nature and extent of the problem.
While measuring corrosion at a single
point is not nearly as valuable as measuring it throughout the process, most
devices are designed for single-point
use. In some plants, where corrosion
monitoring is needed, it is lacking be-
34-39 CHE 11-07.indd 35
35
10/29/07 5:44:23 PM
Cover Story
cause the installed wiring is either difficult to reach or inaccessible. Wireless
technology enables manufacturers to
monitor multiple points online, in realtime or at regular intervals, providing a more comprehensive picture of
corrosion in the plant.
Like corrosion monitoring, equipment-health monitoring, can be an
expensive proposition. For this reason, it is often reserved for only the
most-critical plant assets. This leaves
a large percentage of plant equipment
with no real health monitoring beyond operator rounds and scheduled
maintenance. Wireless technology can
dramatically lower the cost of implementing equipment-health monitoring, allowing operators to effectively
monitor a greater number of assets in
the plant with an increased economic
return. In a sense, wireless technology creates a middle class of assets
those that fall between the more
critical assets monitored with wired
technology in realtime and equipment
that is checked manually on a regular, but infrequent basis. By bringing
equipment-health monitoring to a
larger number of assets, operators can
increase uptime while reducing costs
for unnecessary maintenance.
As for the wireless worker, mobile
wireless solutions allow personnel to
be more effective by helping them computerize their rounds, reduce transcription errors and send data directly from
the field to the process controller. This
automated route is more efficient and
accurate than transcribing data onto a
clipboard, walking back to the control
room and manually entering it into the
system. In short, mobile wireless solutions enable field workers to monitor
more assets with increased speed and
accuracy for improved plant reliability.
Plant efficiency. Wireless technology also improves plant efficiency
with three key features: efficiency of
implementation, efficiency of people
and process efficiency. The cost savings of wireless technology is obvious. Efficiency of deployment is seen
in the wiring cost savings as well as
the speed of installation. It is not unusual for requests for additional wiring to take weeks to implement and
require the interaction of multiple
departments. Wireless technology can
36
FIGURE 2. A key characteristic of a true mesh network is its ability to self heal. If
part of a network fails, the signal is rerouted through other points, ensuring that critical information is delivered
greatly simplify the process, deploying

new instruments in minutes instead
of weeks.
Wireless technology also allows
personnel to be more efficient in their
daily routines. As mentioned previously, mobile wireless solutions can
streamline technician rounds and reduce manual errors. Another group of
employees who benefit from this technology is mobile operators those
who need a view of the entire process
from the control room and to conduct
their own rounds in the field. Tablet
PCs and laptops allow operators to
monitor the control room while walking through the plant.
Another emerging area that can
help personnel work more efficiently
involves the use of digital cameras
for data collaboration. During rounds,
for example, operators visually inspect certain pieces of equipment
for damage. Wireless users, however,
are starting to replace these manual
checks with digital video cameras
that transmit signals back to the control room.
A third area where wireless can
make a significant contribution is process efficiency additional measurements provided by wireless technology allow the operators to run their
processes more efficiently and improve
yield and throughput. Using the tank
farm as an example, an ethanol plant
that uses manual inspections may only
partially fill its tanks to avoid any risk
of overflow. Wireless instrumentation

enables operators to monitor the levels
more accurately and increase throughput without the worry of a spill.
Time to mesh?
A mesh network is considered the

most comprehensive of industrial
wireless solutions currently available. In general, there are two types
of mesh networks: sensor meshes and
backbone meshes. In sensor meshes,
series of sensors communicate with
one another in a localized area and
transmit signals back to the host
system. Backbone meshes typically
involve powered nodes that communicate with each other across wider
distances, connecting various parts of
the plant together. These nodes allow
thousands of devices from field instruments, mobile worker devices, and
even voice and video communication
to co-exist on a single network infrastructure (Figure 1).
Another key characteristic of a true
wireless-mesh network is its ability
to self heal. That is, if part of the
network fails due to an incident such
as a backhoe crashing into a node,
the signal is rerouted through other
points to ensure that critical information, such as process data, is delivered
(Figure 2).
Typically, processors choose to employ a multifunctional mesh network
based on these criteria: First, consider
the number of points a company wants
34-39 CHE 11-07.indd 36
10/29/07 5:44:47 PM
Decreasing Costs, Increasing Safety and Compliance
hemical facilities are volatile environments due to the nature

of their products. Without proper safeguards, these products
pose a hazard to employees and the surrounding environments. Wireless technology can help to alleviate this hazard
as well as bring plants closer to compliance with strict government
and industry regulations. In this case, a plasma-based pharmaceutical company was searching for a way to better monitor its
alcohol tank levels and reduce the safety risks to employees.
Trains deliver virgin alcohol to the facility, where it is unloaded
into 50-year-old, 10,000-gal storage tanks that stand about 15
ft high. Over the next week, the alcohol is processed, refined
and cleaned before being shipped to distributors. Previously, the
method for measuring the alcohol levels within the tanks involved
wooden sticks with lines marking every quarter inch. Each day,
employees would walk up narrow stairways to the tops of the
storage tanks, open a six-inch portal and lower the sticks into the
alcohol. This situation posed a potential safety risk to employees
who would manually check the levels, as the intense alcohol concentration increased the risk of a spark.
There also was an environmental concern. Because the tanks sat
outdoors, the company needed to monitor how much vapor the
tanks released into the air to meet U.S. Environmental Protection
Agency (EPA) regulations.
The problem was three-fold: the company was searching for
a system that would lessen the safety risk to employees, remain
to monitor and the geographic dispersion of those points. Quite simply, the
more physical areas a company wants
to monitor within the plant, the more
economically viable the mesh network.
Second, consider the value of reliable
communications to the company. Some
processors put a premium on reliable
communications. Mesh networks, by
definition, offer multiple redundant
paths. This increases reliability compared to non-meshing architectures.
For example, a major petroleum
refiner in North America installed a
mesh network solution to reduce operating expenses as well as to save
on the cost of running wires over long
distances to monitor tank-farm areas.
The network gives field personnel the
ability to monitor the process through
operator-room displays on tablet PCs,
even when they are out and about in
the refinery. Using this mobile display,
the operator can view and acknowledge alarms, tweak valves and see the
effects in realtime.
Similarly, another refiner with an
instrumented tank farm on the extreme edge of its property saved more
than $1 million in wiring costs by
wirelessly linking the remote location
with the central control room using a
highly reliable mesh network.
A wireless checklist
When choosing new wireless technology for their plants, many companies
make the mistake of planning only for
compliant with EPA regulations and help the company keep better
track of how much alcohol was in the tanks at any given time.
The solution involved a wireless base that sits about 300 yards
from the storage tanks next to a cooling tower on the facility campus. Pressure transmitters that can sense the weight of the alcohol
in the tanks send the data to the wireless base, which then transmits the numbers to a programmable logic controller (PLC). Employees can then view the data at any time on a computer screen
versus having to manually check the levels.
Because running 300400 ft of cable or conduit would have
been cost prohibitive, the pharmaceutical companys preference
was wireless. Besides saving money on wiring, the transmitters
also increase safety and efficiency. The new system reduces the
safety risk by eliminating the need for human interaction at the
tanks. Additionally, the wireless transmitters enable the company
to emit even less alcoholic vapors into the air because workers no
longer have to physically open the tanks to take measurements.
The efficiency of the new wireless system has the customer exploring other possible uses of wireless technology at the facility.
For example, the company is considering options for introducing
wireless technologies into the plants actual processes. Wireless
applications also would eliminate clutter, which would reduce the
amount of time employees spend maintaining the area. Theres
also the issue of keeping the area extremely clean; dirt and dust
will have fewer places to collect without cables or conduit.
current needs. To help plants get ready

for the future, several points must be
considered and questions asked as to
how emerging wireless technology can
best benefit a specific plant.
1. Functionality and applications
Which makes more sense for your facility: Multiple wireless networks or a
single strategic network? This decision
must be made with the future in mind.
Facilities that intend to use wireless
for a limited number of applications
may indeed find that its more cost effective to use single-purpose networks.
If previous buying trends are any indication, though, more companies will
seek to expand their wireless technology bases. In this case, a single, multipurpose network is more efficient.
Will you consider some simple control
applications? Many operators are not
ready for control over wireless today.
But its possible they may want to consider open-loop control for non-critical
assets in the future. It is much easier
to take a wireless system capable of
doing simple control and use it for
monitoring and alerting, than to take
a monitoring network and try to use
it for control. The wrong choice could
limit future flexibility.
Do you want to enable field workers
with handheld devices to access data
and interface with various servers?
Do you want first responders to utilize your wireless network during an
emergency? Again, many companies
may not be ready for these particular capabilities, however, they should
be considered during the planning
stages. Field workers and first responders typically communicate on
Wi-Fi networks. The industrial wireless network could potentially jam
during a plant emergency if it is not
Wi-Fi compatible. Therefore, if you
plan to enable field workers or other
Wi-Fi applications at some point in
the future, it would be wise to select a
compatible network when making the
initial wireless investment.
2. Multispeed support
Do you have requirements for information to reach the control room quickly
for some applications and less rapidly
for others? Certain measurements require fast responses while others can
tolerate a slower update rate. In general, its recommended to ensure your
network can support multiple reporting speeds. If a network only supports
a fast speed, for example, the slower
applications can unnecessarily consume battery life and bandwidth. Conversely, slower-speed networks may
not provide adequate reporting for the
more critical applications.
Can you afford to have alarms transmitted back at the same rate as monitoring information? Many sensor networks report back only on a periodic
basis values are transmitted every
five minutes, for example. Besides
regular updates, however, a very large
34-39 CHE 11-07.indd 37
37
10/29/07 5:45:06 PM
Cover Story
FIGURE 3. Wireless transmitters are strategically located

throughout a facility. In the
early days of wireless, typical
purchases were relatively small
about five transmitters per
project. Today, transmitters
are purchased in much larger
quantities
number of applications also

need to quickly transmit an
alert or alarm when a certain threshold is passed. For
slower reporting rates, it may
also be necessary for operators to get a reading before
the next scheduled update.
For both of these reasons, it is
very important to select a system that allows both regular
and on demand updates.
Making An Environmental Impact
tretching about 620 miles, the Rio Colorado starts in the eastern slopes of the Andes Mountains in Argentina and winds its way east-southeast into the Atlantic Ocean. The path it travels
takes it directly through the Puesto Molina production area, a sector that belongs to Rincon de
los Sauces Oil Fields owned by Repsol YPF (Madrid, Spain), a multinational oil and gas company.
At the Puesto Molina area, the Rio Colorado is the physical boundary between the Mendoza and
Neuquen provinces.
The Economic Unit Rincon de los Sauces, located in western Argentina, covers an area located
in the northern part of the Neuquen province, south of Mendoza and northwest of Rio Negro. It
consists of mature oil fields where the extraction is done through secondary recovery. Output is
188,000 m3/d gross production with a net petroleum production (35 API) of 11,000 m3/d. The
Puesta Molina production area contains 1,147 producing wells, of which 70% are the mechanical
pumping (AIB) type. There are 787 water-injection wells.
All of these production activities are in line with Repsols commitment to human safety and
environmental preservation. But the company, which operates in more than 30 countries and
produces more than 1.2-million bbl/d, needed to get a little creative, though, when it completed
a major project in 2004.
That year, an underwater pipeline crossing of the Rio Colorado was completed in the Puesto Molina production area. One oil pipeline, two gas pipelines and a 585-m aqueduct were installed
under the river to connect the oil fields on either side.
Security and environmental standards required an accurate monitoring of the pipelines to avoid
possible spills into the river in the event of a pipe breakage. To solve the problem, Repsol implemented continuous monitoring of pipeline pressure and integration into a supervisory control and
data acquisition (SCADA) reporting system as part of the control system.
The company examined two options for monitoring pressure in the pipelines: instruments that
were wired and instruments that were wireless.
At the Mendoza Head, Repsol used pressure transmitters with 420-mA outputs to sense the
pressure; it also installed a remote terminal unit (RTU) to send the data to the SCADA system.
Meanwhile, at the Neuquen Head, the company used the same type of transmitters, but used wiring and cable to connect them to an existing RTU located in a water-injection well 50 m away.
After completing engineering design concepts for both options, Repsol chose the wireless implementation because of its lower installed cost versus the traditional wired implementation. In this
case, the mounting and startup costs were reduced from $17,840 to $11,300 a savings of
36.7%. Repsol used an existing RTU near the Neuquen Head to mount a radio base and use wireless pressure transmitters in both heads.
The wireless option also boasts greater data reliability, which was achieved by eliminating
data transmission faults caused by wiring, marshalling panels and junction boxes. Additionally,
the high-reliability wireless solution had an approximately 50% reduction in maintenance costs,
considering there werent any wires, panels or boxes to maintain. The transmitters also feature
auto-diagnose capability and easy configuration.
For instrumentation and controls, Repsol chose a variety of products including a distributed control system, wireless pressure transmitters and other transmitters with 420-mA output to monitor
its pipelines with greater accuracy and security. For instance, the centerpiece of the project was
a wireless pressure transmitter, which transmits data securely within a range of 2,000 ft. With a
battery life of 35 years, this device is geared for applications with no access to power, as well as
those in hazardous and remote locations, where instrumentation changes are frequent or readings are usually done manually.
3. Reliability
Can your operation survive
without the information conveyed wirelessly (think longterm as well)? Operators are
proven to be more effective when they
have more information to make decisions. Wireless is a proven technology
that can help deliver this information.
4. Self-contained and predictable
power management
When most users consider wireless
deployments, they understand the upside of no wiring, but they also envision the downside of having to change
many batteries in industrial devices
throughout the facility.
How long do you want your wireless
devices to be self powered? The maintenance expense of swapping batteries
should not negate the cost savings of
less wiring. Typically users are asking
for at least a 35 year battery life. It
doesnt do you any good to save money
38
on wiring if the batteries need replacing every three months.

Do your wireless devices require addon products to maintain and install
to meet reporting rate needs? Many
vendors quote the battery lifetime at
a very low reporting life. For example,
a vendor may quote a five-year battery life at a one-minute reporting
rate. When selecting wireless products, start with the reporting rate you
require and then ask for the battery
lifetime at that rate. Typically, a fivesecond reporting rate is a good baseline. This will eliminate the need to
add external batteries to minimize
maintenance requirements.
Is a predictable maintenance schedule
important to you? Certain wireless de-
signs consume battery power at a very

deterministic, and therefore predictable, rate. Other systems have non-deterministic battery consumption, and
can have widely varying and unpredictable battery replacement cycles
for similar sensors in the same plant.
To minimize maintenance expense,
operators should select systems with
deterministic battery consumption.
5. Scalability
How many devices can your network
handle, and will that be enough for the
networks lifetime? Planning for future
growth should almost always be a consideration. Although many wireless
users begin with very limited wireless
needs, those needs can grow exponen-
34-39 CHE 11-07.indd 38
10/29/07 5:45:28 PM
tially once they begin to see the benefits of wireless technology.

How scalable do you want your network to be? For operators who want to
start small and grow, it is important
that the system selected can scale
to meet future requirements. Not all
systems scale the same way. Depending on the design, some systems can
grow very large with minimal performance impact, while other systems
quickly degrade after a small number
of devices.
6. Investment protection and application integration
Can your wireless network serve many
application interfaces? Will your next
choice support existing wireless devices? Wireless is not just about supporting legacy devices. Companies
also need flexibility to support future
protocols that might not be in use in
the plant today.
Many plants reap benefits from
having previously deployed multiple application interfaces such

as Modbus, OPC, HART, Foundation
Fieldbus, Profibus, Ethernet and
wireless products throughout the facility. Usually, plants contain multiple
application interfaces driven by different departments. Many users also
want information from their wireless
devices to utilize legacy fieldbus protocols and applications. The ability to
easily interface a network with legacy
applications is ideal because the network will service the entire operation
not just a single department.
Standards on the way
Several organizations are drafting

wireless recommendations and standards as well as offering solutions to
help wireless users find the best solutions for their applications. Emerging
standards will provide some guidance
for wireless technology choices. However, with various solutions available
now and on the horizon, CPI companies can realize the benefits of wireless-enabled applications.
Deploying wireless technology with
a defined strategy will enable an infrastructure that can deliver benefits
above and beyond the savings on wiring costs. The right decision will help
improve safety, optimize the plant and
ensure compliance.
Edited by Deborah Hairston
Author
Jeff Becker is director of
global wireless business for
Honeywell Process Solutions
(2500 West Union Hills Drive,
Phoenix, AZ 85027; Phone
602-313-5000; Web: www.
honeywell.com), where he is
responsible for the companys
wireless business. His career
spans a variety of engineering, sales, marketing, and
general management roles
ranging from startups to companies such as
3Com, Intel, and Ingram Micro. Jeff holds a B.S.
in electrical engineering from the Univ. of California at San Diego.
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34-39 CHE 11-07.indd 39
39
10/31/07 4:54:33 PM
Feature Report
The Importance of Intensive
Steam Trap Management

Joe Radle
Spirax Sarco, Inc.
team traps are an integral part

of steam systems in the chemical
process industries (CPI). Steam
is commonly used to add energy
into a process through its latent heat
(steam heat), while the resultant sensible heat (hot condensate) drains
through steam traps. The operation of
these traps influences the entire steam
systems function and reliability.
Steam trap operation has a bearing
on the following:
Process controllability
Production capacity
Cycle time
Energy consumption
Emissions (carbon footprint)
Safety
Downtime
There are three possible types of
steam traps in process facilities: drip
traps, tracer traps and process traps.
Drip traps help ensure that high quality steam serves the processes through
the effective draining of the mains.
They also protect the distribution system by reducing the chance of water
hammer. Tracer traps keep process
fluids flowing properly in the transmission pipelines connecting the processes, around the process and to and
from storage tanks. Process traps ensure that the process is operating both
effectively and efficiently by removing
the condensate as it forms without the
loss of live steam. It is important that
the steam trap be the right type for
the application and is sized properly
for that application.
Process traps comprise the highest
potential for losses and cost as related
to the process function. When a process trap fails, it usually affects the
process function, and the trap must
be replaced or repaired as soon as possible. Even if the failure does not affect the process, the trap could waste
steam until the failure is detected and
40
Payback is rapid,
energy and maintenance savings are attractive,
and the uptime assurance is incalculable in value
replaced. Drip and tracer traps, installed in large numbers within most
systems, have the highest potential
for energy loss. Since they normally
do not affect the process when failed,
they tend to be overlooked.
When steam traps malfunction
Steam traps function by removing condensate and non-condensable gases as

they form within the process during
the transfer of latent heat into the
process. A properly selected and sized
trap is the best strategy for reliability
and minimum steam leakage in the
event of a failure.
When process traps malfunction, the
effects are wide ranging. A failed-open
process trap dumps live steam needlessly to the condensate recovery system, with serious degradation in thermal efficiency. The effect is even more
critical when the condensate loop is
not closed, since makeup water must
be chemically pretreated and heated.
A trap which has failed completely or
partially closed results in water hammer and wet steam, increased maintenance, longer startup times or total
failure to heat at all.
As traps malfunction, the boiler
emissions load rises to make up for
lost heat. For each gallon of heavy fuel
oil burned unnecessarily to compensate for a steam leak, approximately
25 lb of carbon dioxide are emitted to
the atmosphere.
A failed-open trap poses a risk of
personnel exposure to live steam. A
failed-closed trap allows a buildup
of condensate to occur, with a risk of
injury or damage caused by water
hammer, necessitating downtime and

expensive repairs. In cold climates,
excess venting can result in icing and
potential hazards to personnel.
The significance of trap failure
The massive scale of a typical chemical

process plant magnifies the impact of
steam trap management. Assume that
a steam traps life cycle is seven years.
After the first seven years of the life of
the plant, an average of almost 15% of
the traps will fail in any year. With an
annual maintenance campaign, some
of the traps will fail just after being
checked and some just before the next
check. On average, the 15% can be said
to have failed for half the year, or 7.5%
of traps failed for the whole year.
For the operation team to understand the economic impact of a failure,
an actual scenario can be instructive.
Consider the case of a steam-main
drip trap that fails in rapid cycle. This
thermodynamic style, reduced-port
model operates with a steam pressure
of 100 psig. This trap could be passing 6.2 lb/h on a 24-h basis. With a
steam cost of $8 per thousand pounds
of steam produced, that cost would be
$435 per year if the trap went totally
unchecked. In a correctly sized trap,
the losses would be less; if seriously
oversized, the losses would be considerably higher.
Usual steam trap failure modes
Increasing attention is being paid in

modern plants to means of assessing
steam trap performance. It is essential
to understand the mode of operation of
each type of trap when operating and
40-43 CHE 11-07.indd 40
10/26/07 5:40:56 PM
Table 1. Steam Trap Operation

Trap type
Mode of Operation
Normal
failure mode
No load
Light load
Normal load
Full or overload
Float and
thermostatic
No discharge
Usually continuous; may cycle
Usually continuous; may cycle
Continuous
Variable leakage;
air vent open
Inverted bucket
Dribble
Intermittent
Intermittent
Continuous
Open
Balanced pressure thermostatic
No discharge
Dribble
Intermittent, may
blast
Continuous
Variable or open
Bimetallic
thermostatic
No discharge
Usually dribble
May blast
Continuous
Variable leakage
or open
Impulse
Dribble
Usually
continuous
May blast
Continuous
Open
Disc
thermodynamic
No discharge
Intermittent
Intermittent
Continuous
Rapid cycle or
Open
Inverted
bucket
Impulse
Bimetallic thermostatic
Float and thermostatic
Figure 1. Float and

thermostatic traps, shown
here, have the ability to
operate over a wide range
of flow and pressure.
They provide constant
and consistent levels of
condensate with no steam
loss and they operate in
relation to the saturated
steam pressure/temperature curve. A thermostatic
air vent removes air rapidly
on startup
Figure 2. In inverted bucket traps, the

operating force is provided by steam
entering under the bucket and being
contained within an inverted bucket
causing it to float in condensate that
surrounds the bucket itself. The bucket
is attached to a lever and pivot point. A
valve head and seat are located at the
top of the trap. When the bucket sinks,
it opens the valve allowing condensate
to flow. A small hole in the bucket allows for air venting and also allows
some small amount of steam to flow
when failed, and then to select a test

method capable of correctly detecting
a failure.
Failed traps generally leak to varying degrees depending on the trap
capacity and type of failure. Any trap
with enough dirt accumulation can
plug and fail closed. Small capacity
traps, with their smaller passages, are
more prone to dirt plugging.
An indication of steam trap condition can be obtained by observation.
Table 1 shows the various types of
steam traps, their behavior under various steam loadings and typical failure modes, presented in greater depth
as follows:
Float and thermostatic. These traps
(Figure 1) generally fail with leakage
through the head and seat on the float
mechanism. The mechanism can stick
Figure 3. Impulse
traps, in the thermodynamic family, have
a piston instead of a
disc. The piston has
a constant bleed hole
through its stem and
seating disk that relieves the pressure
above and allows the
valve to open to discharge
because of wear or fail partially closed

if the float is damaged or leaks. Wearing of the thermostatic air-vent head
and seat can cause leakage, or the air
vent can lose its fill, allowing the trap
to fail open.
Inverted bucket. These traps (Figure
2) fail open, with leakage across the
head and seat. The trap can blow completely open under three scenarios: 1)
if the water seal is lost within the trap
due to excessive wear of the head and
seat; 2) sudden changes in pressure; or
3) if the trap is misapplied by oversizing. Since the head and seat are at the
top of the trap, clogging is rare except
in the dirtiest of systems.
Impulse. This trap (Figure 3) generally fails with leakage across the
metal head or seat. The trap can fail
closed if the small bleed port in the
Figure 4. Bimetallic thermostatic traps usually have

a valve on the outlet side.
Bimetal strips or disks of dissimilar stainless steels that
can flex when heated by high
temperature condensate pull
the valve head onto the seat.
When the condensate cools,
the bimetals relax allowing
the valve to open. Bimetal
traps backup some condensate by design
piston plugs with debris.

Bimetallic thermostatic. This trap
(Figure 4) normally fails with head or
seat leakage caused by wire drawing
of the metal components. The trap can
also fail closed if dirt accumulates on
the bimetal plates used in stacked plate
types. Small passages make this design
susceptible to clogging by debris.
Disc thermodynamic. The thermodynamic trap (Figure 5) typically fails
from wear on the disc and seat, resulting in rapid-cycle operation. In cases
of excessive wear or debris lodgment,
the trap can fail open. However, this
type plugs only on the dirtiest of systems because blast discharge tends to
make the trap self-cleaning.
Balanced pressure thermostatic.
Head and seat leakage are the most
common failure mode for this trap
40-43 CHE 11-07.indd 41
41
10/26/07 5:41:18 PM
Feature Report
(Figure 6), but the thermostat can
fail closed if it sees superheat or leaks
while the trap is closed. The trap could
also fail open if the bellows or diaphragm loses its fill or is damaged by
water hammer.
Disc thermodynamic
with strainer
Balanced pressure
thermostatic operation
Manual status monitoring
Operational managers who understand the impact of trap failure should

encourage vigilance on the part of
operators, especially where traps
discharge to grade. Noticing and correcting an obviously leaking trap can
greatly reduce energy losses between
trap surveys. Commonly, process traps
flow into a local vented flash tank. Operators should be primed to notice a
significant increase in venting, so that
an inspection can be scheduled to test
the traps feeding the tank.
Trap location and type affect the
type of condition monitoring best used.
Different considerations exist for each
type of trap and for its operating conditions. Manual observation is the most
widely used method being employed
today. It is important that technicians
be trained to test the various types of
traps and become proficient in the test
equipment to avoid typical erroneous
results. A trained maintenance person
knowing the different types of traps
and how they discharge is the best assurance of an accurate assessment.
Visual assessment. Visual inspection is practical if the trap has an open
discharge to grade; or if test tees and
return isolation valves are in place.
Modern universal trap stations allow
for easy visual testing on drip and
tracer traps. Process traps, because of
high flowrates, are difficult and potentially hazardous to test visually. The
best way to test a process trap visually
is when the process fluid side is not
flowing and the steam side has a very
low condensation rate. With the trap
throttled back to a low level, blowing
through would be obvious.
Ultrasonic discharge sounds. A
sonic gun or mechanics stethoscope
can be used to listen to the flow coming
from the trap. This method is accurate,
especially with an on/off-type steam
trap. The readings can be harder to
detect on modulating type traps unless
the condensate load can be removed,
leaving the trap on live steam.
42
Disc thermodynamic
in operation
Figure 5. The thermodynamic trap is the only
type of steam trap that has a distinctive snap
open-closed operation. The function of the trap
uses flow velocity, flash steam and ratio of
areas to close the trap. Once the trap closes,
cooler condensate forming at the trap inlet reduces pressure in the control chamber allowing
the inlet pressure to reopen the trap. This is the
easiest trap to determine if it is working properly by visual or audible testing. The trap has
zero loss when working properly
Temperature testing. Reliance upon

temperature measuring devices often
results in erroneous conclusions. To be
sure, temperature readings definitely
detect traps failed closed or turned off.
A leaking trap, however, may show no
temperature differential across the trap
(inlet versus outlet). Remember that
the steam pressure in the downstream
piping determines the temperature in
the downstream piping. If several traps
discharge into a common return (as is
often the case), the downstream temperature is a mixture of several traps.
One trap blowing through can make
all the traps on that line appear to be
leaking or failed. Alternatively, if the
return piping is correctly sized with
no backpressure, a failed trap could be
passed as good on the basis of no measurable temperature rise.
Ultrasonic plus temperature. Ultrasonic sounds and temperature together offer the most useful condition
indication. Temperature measurement
detects failed-closed or blocked-off
traps, and ultrasonic sounds give an
indication of the trap function. Using
both will ensure that the ultrasonic
tester does not pass a cold trap or isolated trap as good. The temperature
gun can also help identify different
operating pressures, since many lines
are not marked.
Figure 6. The balance pressure thermostatic capsule or bellows is filled with a liquid, which
boils a few degrees below water.
The trap closes when the liquid
expands and pushes the valve
head closed. As the condensate
cools, the thermostat liquid contracts opening the valve to allow
flow. Thermostatic traps discharge sub-cooled condensate
Automatic status monitoring
Most process facilities would be well

advised to evaluate an automated
monitoring system, especially in distribution loops in the 460-psi class, or
any process involving more than 100
traps. Other conditions that make automatic monitoring desirable include
inaccessible traps, traps in lengthy
steam tunnels and traps placed in unsafe, confined spaces.
Online conductivity and condensate temperature monitoring. This
monitoring strategy works well in
applications where traps are in nonfreezing, non-explosive environments.
Indoors, any type or style trap can
be monitored by conductivity, which
senses directly what is going on inside
the system. As long as the trap is operating properly, there will always be
condensate covering the sensor. The
minute the sensor is uncovered by
blowing steam, the circuit is broken
and a fail signal is transmitted.
Online temperature and ultrasonic
monitoring. Temperature monitoring, combined with ultrasonic sensing, checks trap-flow characteristics as
well as temperature, with the ability
to detect failed-open, failed-closed or
blocked-out conditions. The addition of
a pressure switch enables determination between blocked out and failed-
40-43 CHE 11-07.indd 42
10/26/07 5:41:45 PM
Table 2. Cost Benefits

Of Modular Drip Stations
Cost factor
Pipedin trap
Universal
connector trap
Universal
connector
station
Materials
$435
$456
$556
Labor
$270
$150
$30
Total installed cost
$705
$606
$586
Materials
$192
$170
$170
Labor
$60
$7.5
$7.5
Total replacement
cost
$252
$177.5
$177.5
INSTALLATION
REPLACEMENT
Installation basis. Piped In: Materials include 2 unions, 8 nipples,

4 gate valves, 1 strainer, 1 trap, 1 tee; making 18 connections. Universal trap: Materials include 4 nipples, 3 gate valves, 1 trap, 1
strainer/blowdown valve, 1 tee; making 10 connections. Universal
connector station: Materials include 1 station, 1 trap; making 2
connections.
Replacement basis. Piped In: Materials include 2 nipples and 1
trap; making 4 connections. Universal Trap And Station: 10 min.
labor.
Connections at 1/3 h per connection; labor $45/h.
closed at cool temperatures. Ultrasonic

fluctuations are best used with on/offtype traps, where the measurement is
easily defined. However, results are not
as good on traps that modulate, especially in process applications. Special
precautions are needed in outdoor and
explosion-hazard areas, and in some
locations this monitoring strategy cannot be used at all.
Management programs
A useful tool in steam trap management is the steam trap survey. Accomplished at regular intervals, the survey involves identifying, tagging and
testing every trap (Figure 7). The surveyor reviews the trap application to
confirm suitability, function and operational condition. Failed traps are highlighted, and steam losses calculated,
giving payback times on replacement
of the failed traps. The survey also
highlights key areas where energy
savings could be made in the boiler
house and on the condensate return
system. The survey report targets and
prioritizes areas of the plant which,
with further investigation, could lead
to greater savings and improvements.
The results are used to build a database of traps useful in managing predictive and preventive maintenance,
spares and parts inventory.
Figure 7. A steam trap survey involves identifying, tagging and

testing every trap
Labor can be a significant component

within a steam-trap maintenance program. This can be offset somewhat by
installing modular-style trap stations
on drip and tracer applications. These
stations connect the trap through universal connectors in place of pipe connections. Although the installed cost
of the trap itself is slightly higher, the
universal connector and the universal trap station reduce lifecycle costs.
Table 2 summarizes these savings.
Process traps, since they vary widely
in size, must be piped with NPT,
flanged or socket-weld connections.
In most cases, process traps should be
rebuilt inline with spare mechanisms
and new gaskets, since this cost is significantly lower than the replacing the
entire trap.
The plant should also have in place
an organizational mechanism for remediation action and implementation.
A team comprising process engineering, operations and maintenance usually works best, since survey remediation involves on all three functions.
Uptime insurance
When a process steam trap does not

apply energy at a constant rate, uncertainty enters the process, with a risk of
product underheating and off-grade or
totally destroyed product. Even if con-
trols are present to quantify and manage the energy application, a failed
trap will still result in slower heating,
longer cycle time, lower unit process
output, reduced production capacity or
total production upsets. The impact of
this situation, in turn, is often missed
production schedules. This risk alone
easily justifies CPI facilities undertaking an active steam-trap management
program, beginning with a complete
trap survey to benchmark the steam
loop against best practices. Payback is
rapid, energy and maintenance savings
are attractive, and the uptime assurance is incalculable in value.
Author
Joe Radle is a steam trap
product manager for Spirax
Sarco, Inc. (SSI; 1150 Northpoint Blvd., Blythewood, SC
29016. Phone: 800-575-0394;
Fax: 803-714-2222; Email:
InsideSalesLeads@Spirax.
com). A third-generation SSI
employee known as Steam
Trap Joe, Radle has 35 years
of experience in building and
testing steam trap products,
R&D engineering, applications engineering and
steam system troubleshooting. He is listed as the
inventor on one U.S. patent and has one patent
pending. Radle attended Northampton County
Community College and Lafayette College. He is
a member of the Fluids Control Institute, where
he sits on the steam panel that develops industry standards.
40-43 CHE 11-07.indd 43
43
10/26/07 5:42:11 PM

Liquid Density
Of the Elements
A comprehensive tabulation
for all the important elements from Ag to Zr
Carl L. Yaws, Lamar University
iquid density is important to engineers throughout the chemical

process industries (CPI). Knowledge of liquid density is required
in the design of storage vessels. In
hazard analysis, knowledge of liquid
density is required in the design of the
relief valves to protect the system. In
vapor-liquid operations, such as distillation, knowledge of liquid density is
required to determine column diameter. For environmental applications,
knowledge of liquid density is required
to ascertain emissions into air from a

liquid spill.
Results for liquid density as a function of temperature are presented here
for the chemical elements. The coverage for the elements is comprehensive
ranging from Ag to Zr and includes the
widely used diatomic elements (Br2, Cl2,
F2, H2, I2, N2, and O2) and inert gases
(Ar, He, Ne, and Xe). The results are
useful in design, safety, environmental,
and simulation applications in chemical
processing and petroleum refining.
Table 1.
density = A B
CAS No.
A
- (1- T )n
C

%BUB
&RVBUJPO

5FNQFSBUVSF ,

Figure 1. The good agreement between the correlation curve and experimental data can be seen in this graph of
the liquid density of nitrogen
Correlation of liquid density
The modified form of the Rackett

equation was selected for correlation
of saturated liquid density as a function of temperature:

(1)
(1 T ) n
density A B C
where density is the saturated liquid
density (g/mL), A, B, C, and n are regression coefficients for chemical compound and T is the temperature (K).
The results for liquid density are
given in Table 1. The tabulation is arranged by alphabetical order (Ag, Al,
Ar, ... , Zr). This provides ease of use in
quickly locating the data by using the
chemical formula. The compound name,
CAS No. (Chemical Abstracts Registry
(density, g/mL; T = temperature, K)

C
n
Tmin
Tmax
No. ID
Formula Name
13
Ag
silver
7440-22-4 0.31819 0.03098
6,410.00 0.13648 1,234.00
6,410.00
1,2 1,234.00
9.296
77
Al
aluminum
7429-90-5 0.69200 0.27351
9,300.00 0.50000
933.25
9,300.00
1,2 1,173.15
2.325
200
Ar
argon
7440-37-1 0.53120 0.28600
150.86 0.29840
83.78
150.86
1,2
1.419
202
As
arsenic
7440-38-3 0.62605 0.05595
1,673.15 0.28571 1,090.15
1,290.15
1,2 1,090.15
5.286
256
Au
gold
7440-57-5 8.35557 0.44663
4,398.00 0.28571 1,337.33
4,398.00
1,2 1,337.33
17.282
283
boron
7440-42-8 0.72680 0.30000
7,934.59 0.28571 2,348.15
2,548.15
1,2 2,348.15
2.160
416
Ba
barium
7440-39-3 1.11110 0.30000
3,572.13 0.28571 1,000.15
1,200.15
1,2 1,000.15
3.325
530
Be
beryllium
7440-41-7 0.02893 0.01109
5,205.00 0.28571 1,556.00
2,000.00
1,2 1,556.00
562
Bi
bismuth
7440-69-9 2.01611 0.18801
4,620.00 0.30873
544.54
4,620.00
1,2
544.54
10.064
Br2
bromine
7726-95-6 1.18377 0.29527
584.15 0.32950
265.85
584.15
1,2
265.85
3.214
11 637
carbon
(amphorous)
7440-44-0 0.31475 0.10000
6,810.00 0.28571 4,765.00
4,965.00
1,2 4,765.00
1.611
12 639
graphite
7782-42-5 0.63887 0.27136
6,810.00 0.28571 4,765.00
6810.00
1,2 4,765.00
1.611
13 675
Ca
calcium
7440-70-2 0.07756 0.04927
3,267.00 0.11441 1,115.00
3,267.00
1,2 1,115.00
1.368
14 776
Cd
cadmium
7440-43-9 3.72607 0.43396
2,291.00 0.28571
594.05
2291.00
1,2
8.017
15 830
Ce
cerium
7440-45-1 2.13760 0.31027 11,993.80 0.28571 1,071.15
1,271.15
1,2 1,071.15
6.680
16 899
Cl2
chlorine
7782-50-5 0.56600 0.27315
1,2
172.12
1.723
17 916
Co
10 633
%FOTJUZPGMJRVJE HN-

Feature Report
Engineering
Practice
417.15 0.28830
1,72.12
417.15
Code
T, K
83.78
594.05
Density
@T
1.690
cobalt
7440-48-4 2.51864 0.25033
7,398.48 0.80000 1,768.15
7,398.48
1,2 1,873.15
7.540
18 1035 Cr
chromium
7440-47-3 2.13536 0.30000
8,560.93 0.28571 2,180.15
2,380.15
1,2 2,180.15
6.460
19 1124 Cs
cesium
7440-46-2 0.28361 0.14024
2,048.10 0.28571
301.65
2,030.00
1,2
301.65
1.853
20 1169 Cu
21 1302 D2
22 1307 Dy
copper
deuterium
dysprosium
7440-50-8 2.63621 0.30161

7782-39-0 0.06700 0.31500
7429-91-6 2.62400 0.29728
5,123.00 0.28571 1,357.77

38.35 0.28571
18.73
8,561.50 0.28571 1,685.15
5,123.00
38.35
1,885.15
1,2 1,673.15
1,2
18.73
1,2 1,685.15
7.690
0.1730
8.200
44
44-46 CHE 11-07.indd 44
10/26/07 5:36:52 PM
No ID
Table 1 (Continued).
Formula Name
CAS No
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
1332
1369
1409
1420
1575
1610
1637
1709
1739
1740
1771
1841
1873
1877
1917
1960
2162
2168
2203
2316
2335
2464
2548
2678
2781
3019
3057
3091
3092
3198
3200
3234
3235
Er
Eu
F2
Fe
Ga
Gd
Ge
H2
He
Hf
Hg
Ho
I2
In
Ir
K
Kr
La
Li
Lu
Mg
Mn
Mo
N2
Na
Nb
Nd
Ne
Ni
O2
Os
P
P
erbium
europium
fluorine
iron
gallium
gadolinium
germanium
hydrogen
helium-4
hafnium
mercury
holmium
iodine
indium
iridium
potassium
krypton
lanthanum
lithium
lutetium
magnesium
manganese
molybdenum
nitrogen
sodium
niobium
neodymium
neon
nickel
oxygen
osmium
phosphorus (white)
phosphorus (red)
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
3483
3571
3637
3641
3650
3691
3773
3781
3828
3880
3940
3941
3991
4023
4065
4083
4140
4303
4332
4461
4517
4550
Pb
Pd
Pm
Po
Pr
Pt
Ra
Rb
Re
Rh
Rn
Ru
S
Sb
Sc
Se
Si
Sm
Sn
Sr
Ta
Tb
lead
palladium
promethium
polonium
praseodymium
platinum
radium
rubidium
rhenium
rhodium
radon
ruthenium
sulfur
antimony
scandium
selenium (gray)
silicon
samarium
tin (white)
strontium
tantalum
terbium
density = A B
- (1- T )n
C

C
n
Tmin
Tmax
code
T, K
7440-52-0
7440-53-1
7782-41-4
7439-89-6
7440-55-3
7440-54-2
7440-56-4
1333-74-0
7440-59-7
7440-58-6
7439-97-6
7440-60-0
7553-56-2
7440-74-6
7439-88-5
7440-09-7
7439-90-9
7439-91-0
7439-93-2
7439-94-3
7439-95-4
7439-96-5
7439-98-7
7727-37-9
7440-23-5
7440-03-1
7440-00-8
7440-01-9
7440-02-0
7782-44-7
7440-04-2
7723-14-0
7723-14-0
2.75200
1.57191
0.57014
1.99446
0.47740
2.68561
1.61357
0.03125
0.06930
3.75257
5.73614
2.66880
1.63746
0.55791
6.41388
0.18711
0.91799
1.50549
0.11037
3.32517
0.07780
2.09497
3.14663
0.31422
0.19819
2.48435
2.02652
0.48504
2.56376
0.43600
6.48474
1.02120
0.96106
0.29872
0.29797
0.28587
0.22457
0.07625
0.34705
0.26102
0.34730
0.41860
0.30000
0.40708
0.29781
0.33313
0.07561
0.30000
0.20637
0.28840
0.23941
0.19951
0.29161
0.03010
0.30000
0.30000
0.28610
0.19553
0.30000
0.28826
0.30670
0.25892
0.29060
0.30000
0.50058
0.80200
9,714.25
5,150.00
144.12
9,340.00
7,620.00
11,309.81
9,803.00
33.18
5.20
2,1687.96
1,735.00
9,067.21
819.15
6,730.00
15,035.00
2,223.00
209.35
9,511.00
3,503.00
4,128.66
2,241.04
6,902.82
9,620.00
126.20
2,573.00
17,904.10
10,665.10
44.40
6,986.15
154.58
16,878.68
993.75
993.75
0.28571
0.28571
0.28776
0.70000
0.28571
0.28571
0.59646
0.27560
0.24100
0.28571
0.25997
0.28571
0.33550
0.28571
0.28571
0.35970
0.29390
0.28571
0.35129
0.28571
0.28571
0.28571
0.28571
0.29660
0.37200
0.28571
0.28571
0.27860
0.70000
0.29240
0.28571
0.66360
0.09118
1,802.15
1,095.15
53.48
1,811.00
302.91
1,586.15
1,210.40
13.95
1.76
2,506.15
234.29
1,747.15
386.75
429.75
2,719.15
336.35
1,15.78
1,191.15
453.69
1,936.15
923.15
1,519.15
2,895.15
63.15
370.95
2,750.15
1,294.15
24.56
1,728.15
54.35
3,306.15
317.55
853.15
2,002.15
1,295.15
144.12
9,340.00
7,620.00
1,786.15
9,803.00
33.18
5.20
2,706.15
1,735.00
1,947.15
819.15
573.15
2,919.15
2,223.00
209.35
1,391.15
3,503.00
2,136.15
1,023.15
1,719.15
3,095.15
126.20
2,573.00
2,950.15
1,494.15
44.40
6,986.15
1,54.58
3,506.15
993.75
953.15
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,802.15
1,095.15
53.48
1,923.15
302.91
1,586.15
1,210.40
13.95
1.76
2,506.15
234.29
1,747.15
386.75
429.75
2,719.15
336.35
115.78
1,191.15
453.69
1,936.15
923.15
1,519.15
2,895.15
63.15
370.95
2,750.15
1,294.15
24.56
1,873.15
90.15
3,306.15
317.55
853.15
Density
@T
8.600
4.870
1.706
7.109
6.078
7.400
5.585
0.0776
0.152
12.000
13.630
8.340
3.976
7.031
20.000
0.828
2.449
5.960
0.512
9.300
1.579
6.430
9.330
0.870
0.928
7.830
6.720
1.247
7.595
1.135
20.100
1.745
1.156
7439-92-1
7440-05-3
7440-12-2
7440-08-6
7440-10-0
7440-06-4
7440-14-4
7440-17-7
7440-15-5
7440-16-6
10043-92-2
7440-18-8
7704-34-9
7440-36-0
7440-20-2
7782-49-2
7440-21-3
7440-19-9
7440-31-5
7440-24-6
7440-25-7
7440-27-9
1.73000
3.31600
2.20800
2.76115
2.10880
6.65186
1.49145
0.34600
6.01402
3.40525
1.58779
3.48198
0.20468
1.69927
0.90098
0.75697
1.73001
2.30412
0.68914
0.78222
4.78107
2.44800
0.15282
0.26650
0.30571
0.30000
0.30930
0.26561
0.30000
0.21564
0.30000
0.30000
0.28111
0.30000
0.10440
0.24231
0.29526
0.16124
0.64037
0.28994
0.09454
0.30000
0.30000
0.30358
5,400.00
10,669.07
10,228.86
3,013.08
12,306.26
6,983.00
4,862.82
2,093.00
21,482.82
12,906.61
377.40
15,247.14
1,313.00
5,070.00
8,035.08
1,766.00
5,159.00
5,082.92
7,400.00
4,267.20
19,900.93
11,138.10
0.28571
0.75000
0.28571
0.28571
0.28571
0.70000
0.28571
0.37000
0.28571
0.28571
0.28571
0.28571
0.11400
0.28571
0.28571
0.28571
0.30000
0.28571
0.27000
0.28571
0.28571
0.28571
600.64 5,400.00
1,828.05 10,669.07
1,315.15 1,515.15
527.15
727.15
1,204.15 1,404.15
2,041.55 6,983.00
973.15 1,173.15
312.46 2,093.00
3,459.15 3,659.15
2,237.15 2,437.15
202.15
377.40
2,607.15 2,807.15
388.36 1,313.00
903.78 5,070.00
1,814.15 2,014.15
494.15
694.15
1,685.00 5,159.00
1,347.15 1,547.15
505.08 7,400.00
1,050.15 1,250.15
3,290.15 3,490.15
1,629.15 1,829.15
1,2
1,2
2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
1,2
923.15
1,973.15
1,315.15
527.15
1,204.15
2,073.15
973.15
312.46
3,459.15
2,237.15
202.15
2,607.15
388.36
903.78
1,814.15
494.15
1,687.00
1,347.15
505.08
1,050.15
3,290.15
1,629.15
10.265
10.310
6.900
8.630
6.590
18.745
4.615
1.482
18.900
10.650
4.400
10.900
1.794
6.491
2.800
3.987
2.570
7.160
6.986
2.375
15.000
7.650
(Continues on P. 46)
44-46 CHE 11-07.indd 45
45
10/26/07 5:38:05 PM
Engineering Practice
No. ID
Table 1 (Continued).
Formula Name
CAS No.
density = A B
- (1- T )n
C
78 4570 Tc
technetium
79 4583 Te
tellurium
13494-80-9 1.83626 0.30000
80 4639 Ti
81 4703 Tl
titanium
thallium
7440-32-6 1.38759 0.30000

7440-28-0 1.79212 0.14783
82 4747 Tm
83 4766 U

C
n
Tmin
Tmax
Code
7440-26-8 3.34979 0.30000 17,400.77 0.28571 2,430.15
2,630.15
1,2 2,430.15
922.66
722.66
5.797
6,400.00 0.28571 1,941.15

4,648.06 0.28571 577.15
2,141.15
4,648.06
1,2 1,941.15
1,2
577.15
4.110
11.291
thulium
uranium
7440-30-4 2.88674 0.28545 6,283.16 0.28571 1,818.15

7440-61-1 5.57293 0.30000 13,712.62 0.28571 1,408.15
2,018.15
1,608.15
2 1,818.15
1,2 1,408.15
9.000
17.907
84 4836 V
vanadium
7440-62-2 1.78294 0.30000 11,787.15 0.28571 2,183.15
2,383.15
1,2 2,183.15
5.550
85 4899 W
tungsten
7440-33-7 5.84023 0.30000 14,756.00 0.28571 3,695.15
3,895.15
1,2 3,695.15
17.700
86 4945 Xe
87 4960 Y
xenon
yttrium
7440-63-3 1.10648 0.28552

7440-65-5 1.32860 0.29141
289.74 0.28967 161.36

9,381.32 0.28571 1,795.15
289.74
1,995.15
1,2
161.36
1,2 1,795.15
2.978
4.240
88 4995 Yb
ytterbium
7440-64-4 2.12198 0.31165
4,365.92 0.28571 1,092.15
1,292.15
1,2 1,092.15
6.210
89 5021 Zn
90 5113 Zr
zinc
zirconium
7440-66-6 1.98150 0.27115

7440-67-7 1.90680 0.30000
3,170.00 0.34000 692.70

8,802.00 0.28571 2,128.15
3,170.00
2,328.15
1,2
812.15
1,2 2,128.15
6.427
5.800
A, B, C, and n = regression coefficients of chemical compound

T = temperature, K
Number), and regression coefficients

are provided in the adjacent columns.
The range of application is denoted
by minimum and maximum temperatures (Tmin and Tmax). Temperatures
outside the range of application should
not be used. The next column provides
the code for the tabulation, which is
based on both experimental data and
estimated values. The last two columns
provide a representative temperature
and value for liquid density at the representative temperature.
In preparing the tabulation, a literature search was conducted to identify data source publications for the
elements [111]. Both experimental
values for the property under consideration and parameter values for estimation of the property are included in
the source publications. The publications were screened and copies of appropriate data were made. These data
were then keyed into the computer to
provide a database of values for compounds for which experimental data

are available. The database also served
as a basis to check the accuracy of the
estimation methods. Upon completion
of data collection, estimation of the values for the remaining compounds was
performed. The numerous point values
were processed using a computer program for minimum deviation.
The compilations of CRC [1];
Daubert and Danner [2]; Landolt
and Bornstein [4]; Perrys [5]; and
Yaws [811] were used extensively
for liquid density. Estimates were
primarily based on literature estimated values and proprietary techniques developed by the author. For
the high melting compounds, most of
the data for liquid density are only
available in the region of the melting point. In the absence of data,
the estimates at temperature much
higher than melting point should be
1,2
Density
@T
10.615
722.66
Code: 1 = data, 2 = estimate

Density = density of liquid, g/mL
4,840.00 0.28571
T, K
Tman = maximum temperature, K

Tmin = minimum temperature, K
considered rough approximations.

A comparison of calculated and data
values is shown in Figure 1 for a representative compound. The graph discloses favorable agreement between
equation-derived values and experimental data.
An example
In an industrial application, the liquid

density of nitrogen (N2) at 77.56 K is
required. Calculate the liquid density
of nitrogen at this temperature.
Substitution of the coefficients from
the table and temperature into Equation (1) for liquid density yields:
density = (0.31422).(0.2861)exp[(1
77.56/126.2).2966]
= (.31422).(.2861)exp[(0.38541)0.2966]
= (0.31422).(.26610)0.753683
= (0.31422).(2.5681)
density = 0.807 g/mL
n
References
1. CRC Handbook of Chemistry and Physics,
7586th eds., CRC Press, Inc., Boca Raton,
Fla., 19942006.
2. Daubert, T. E. and R. P. Danner, Data Compilation of Properties of Pure Compounds,
Parts 1, 2, 3, and 4, Supplements 1 and 2,
DIPPR Project, AIChE, New York, N.Y.,
19851994.
3. Encyclopedia of Chemical Technology, 3rd
and 4th eds., John Wiley and Sons, Inc., New
York, N.Y., 19782004.
4. Landolt, H. and R. Bornstein, Zahlenwerte
und Funktionen ans Physik, Chemie, Astronomie und Technik, Springer-Verlag, Heidelberg, Germany, 19712005.
5. Perrys Chemical Engineering Handbook,
6th and 7th eds., McGraw-Hill, New York,
N.Y., 1984 and 1997.
46
6. Saxs Dangerous Properties of Industrial Materials, 10th ed., Vol. 1, 2, and 3, Lewis, R.
J.. Lewis, Sr., editor, John Wiley, New York,
N.Y., 2000.
7. Vargaftik, N. B., Tables on the Thermophysical Properties of Liquids and Gases, 2nd ed.,
English translation, Hemisphere Publishing
Corporation, New York, N.Y., 1975 and 1983.
8. Yaws, C. L. and others, Major Diatomic Gases
(Hydrogen, Nitrogen and Oxygen) Phy.
and Thermo. Prop. (8), Chem. Eng., 82 (2), pp,
99106, January 20, 1975.
9. Yaws, C. L., Physical Properties, McGrawHill, New York, N.Y., 1977.
10. Yaws, C. L., Chemical Properties Handbook,
McGraw-Hill, New York, N.Y., 1999.
11. Yaws, C. L., Matheson Gas Data Book, 7th
ed., Matheson Tri-Gas (Parisppany, N.J.),
McGraw-Hill, New York, N.Y., 2001.
Author
Carl L. Yaws is a professor
of chemical engineering at
Lamar University (Dept. of
Chemical Engineering, P.O.
Box 10053, Beaumont, TX
77710; Phone: 409-880-8784;
Fax: 409-880-2197; Email:
clyaws@my.lamar.edu). Yaws
holds bachelor, master and
doctor degrees from Texas
A&I University and University of Houston. A registered
professional engineer (Texas), he is the author of
30 books and has published more than 640 technical papers. His research interests include technology development, thermodynamic and transport property data, environmental engineering
and process simulation.
44-46 CHE 11-07.indd 46
10/26/07 5:38:32 PM
Engineeering
Practice
PLC Maintenance
Management
PLCs are critical to the success of
CPI processes. These requirements
for proper PLC management
go a long way toward reducing downtime
and unnecessary costs
Don Fitchett
Business Industrial Network
lthough some CPI management may not realize it, PLCs

(programmable logic controllers) are the brains behind
many operations in the chemical
process industries (CPI). A malfunctioning PLC can cause lines, plants
and even operations such as city
bridges and water stations to shut
down. Thousands to millions of dollars could be lost in association with
one PLC that maintenance personnel may not even know exists. Proper
maintenance management of PLCs
is needed to avoid damage to machines and personnel, as well as to
minimize downtime. In every CPI facility, the following questions should
be answered:
What is a PLC?
How many PLCs is your bottom line
depending on?
Do you have an up-to-date list of all
PLC models, part availability, program copies, and other details?
Do you have at least one trained
person per shift to maintain and
troubleshoot your plants PLCs?
Do maintenance personnel work
with PLCs following written company or corporate policy, and procedures?
If any of these questions cannot be answered positively or with confidence,
this article will prove to be a valuable
resource for maintenance management of PLCs.
What are PLCs?
Understanding what PLCs are and

how they work is important not only
for maintenance engineers and technicians, but also for maintenance
managers, plant managers and corporate managers. A PLC is the type
of computer that controls and troubleshoots most machines today. The
PLC can be thought of as the brain
of a machine; without it, the machine
is dead. Just as a doctor asks a patient questions to determine what
is wrong, a maintenance technician
asks the PLC questions to troubleshoot a machine. Using a laptop computer, plant personnel can see what
conditions have to be met in order for
the PLC to cause an action to occur
(for example, turn a motor on). In a
reliable maintenance-management
environment, the technician will use
the PLC as a troubleshooting tool to
reduce downtime.
Technical definition of a PLC. A
programmable controller is a small,
industrial-strength computer used to
control real-world actions based on
its program and real-world sensors.
PLCs replace the networks of thousands of relays that were common in
older electrical panels, allowing maintenance technicians to change the way
a machine works without having to do
any wiring. The program is typically
written in ladder logic, the sequential
control of a process that is similar to
the wiring schematics maintenance

electricians are already accustomed to
working with. Inputs to a PLC can include switches, sensors, bar codes and
machine operator data. Outputs from
the PLC can include motors, air solenoids and indicator lights.
PLC awareness
In an ongoing PLC-related global

maintenance survey, the majority of
participants in 2001 reported being
aware of three to six PLCs in their facilities. Many of the participants are
from large Fortune 500 companies, and
most were managers, who are typically
not exposed to technical operations on
a day-to-day basis. While awareness
was reported for three to six PLCs, it
is likely that most of these companies
have 12 to 30 PLCs in their facilities.
Although the current average number
of PLCs reported is only six to nine, it
shows that the industry as a whole is
gradually becoming more PLC aware.
It is common to learn about a PLC
only once it is malfunctioning, possibly shutting down an entire process
with the clock ticking at thousands of
dollars per hour. Unfortunately, after
the fire is out, it is often on to the
next fire without fully learning what
can be done to avoid costly downtimes
in the future, both in the repaired unit
and in other similar PLCs within the
company.
Although some older electrical pan-
47-49 CHE 11-07.indd 47
47
10/26/07 5:45:29 PM
Table 1. PLC AUDIT FORM
Collected information
Examples and recommended actions
Machine or area name
Warehouse conveyor, pump station 3, strapper 2, line 7, traffic signal west main
PLC program name
1789GAA1, P3, Strap2, 5872443, WestMainTL
Network node address
No two addresses will be the same
Network name
Commonly the same as the program name, but not mandatory
PLC brand
Allen Bradley, Siemens, Schneider, Mitsubishi, DirectSoft, Omron
PLC model number
PLC-5/25, SLC-504, SIMATIC S5, MELSEC FX1N, DL 405
Available spares
Yes on shelf; only in less critical machines; or no
Date program was last backed up
Make program backups part of your semiannual maintenance program
Descriptive copy of program available
Without a descriptive copy of the program, troubleshooting and downtime are

greatly increased
Does PLC have a method for storing

a backup program
EEPROM (electrically erasable programmable read-only memory) or other method

of storing backup program in a chip on PLC
Date program was last changed
Remember to log when outside consultants or OEM make program changes too
Date EEPROM was last burned
Should be saved to EEPROM (burned) after every successful program change
Date battery was last changed
See manufacturers data for recommended change frequency
Other pertinent information
Might be facility location when corporate is using this form
"UZQJDBMSVOHEFTDSJQUJPOGPSUIJTTJNQMJGJFEFYBNQMFSVOH NJHIUSFBEi*GDPOWFZPSJTJONBOVBMPSBVUPNBUJDBOECFJOHUPMEUPNPWF
GPSXBSEBOEOPUJOBMBSNDPOEJUJPO BDUJWBUF PVUQVUUP
UIFDPOWFZPSGPSXBSENPUPSSFMBZu
*GDPOWFZPSJT
JONBOVBM
$POWFZPS
CSBLFJTPO
$POWFZPS
"MBSN
"MBSN
$POWFZPS
GPSXBSE
NPUPSPVUQVU
#
#
5
#
#

%/

$POWFZPSJT
JOBVUPNBUJD
%PXOTUSFBN
DPOWFZPSGVMM
$POWFZPSGPSXBSE
BVUPSFRVFTUFE
5
#
#
%/

els may have only relay panels in them,

most equipment (for example, air compressors) are controlled by a PLC. An
operation that could potentially cause
a process bottleneck is also likely to be
controlled by a PLC. How much would
it cost your company if the bottleneck
or malfunctioning utility shut down a
line, a section of your facility, or even
the entire plant?
Performing PLC audits
Maintaining an up-to-date list of PLC

information is essential to PLC management. The following three-step
process should be followed every six
months to check that all information
is current.
1. Perform a PLC audit: Open every
electrical panel, and write down the
PLC brand, model and other pertinent information
2. Analyze the audit details and risk
3. Act on the analysis
The PLC audit form, shown in Table 1,
48
$POWFZPS
GPSXBSEKPZTUJDL
Figure 2. Example of a descriptive process
illustrates the information that should

be collected, along with examples of
this information and the recommended
actions that should be taken based on
the outcomes of the audit.
Once the basic information from the
plant-wide or corporate audit has been
collected, it is important to analyze
the information in order to develop
an action plan based on risk analysis.
In the risk analysis, bottlenecks and
other factors will help you assign priorities. Starting with the highest priority PLC, additional questions need
to be asked.
Are there spares for the most common PLCs onsite for quick switching
in the event of a malfunction?
Is the original equipment manufacturer still in business? Does it have
personnel available 24 hours a day, 7
days a week?
Is there a backup copy of the PLC
program?
Does the program copy have el-
emental descriptions (Figure 2) so

we can work with it reliably and efficiently?
Do we have the software needed
to view the PLC program? Are our
maintenance personnel trained on
that PLC brand?
By asking these questions and ensuring
that they can be answered positively,
plant managers can avoid unnecessary
risk and guarantee reliability.
Training personnel
Costly downtime due to PLC malfunction can be avoided by providing maintenance staff with sufficient training.
The investment in maintenance training can save a company from much
greater losses. Many facilities schedule most of their knowledge base to be
available during day shifts. At least
one trained person should be onsite
during every shift to work reliably
with PLCs, since greater downtime
occurs during off shifts. Also, consider
47-49 CHE 11-07.indd 48
10/26/07 5:46:00 PM
Procedure for plc management

1. Write PLC policies and procedures into your existing maintenance policy and procedures
2. Train personnel working with PLCs on specific PLC equipment
3. Create backup copies of PLC programs every six months regardless of change status
4. If a PLC program has been changed, perform steps ad. If the
outside vendor changes, these steps should be performed by
maintenance personnel
a. Document the change in the software copy, in the printed
copy and in the CMMS (Certified Maintenance Management) program
b. Store copies of the PLC program on reliable media, such as
a CD or USB
c. Store multiple copies on maintenance laptops, in the maintenance managers office and offsite (corporate)
d. Update EEPROM with the changed program
5. Purchasing future equipment
that baby boomers, the core knowledge base in the industry, are about
to retire, and implementing a training
program for PLC management will
help to prepare other employees.
Training should be sought with two
primary objectives:
1. E
mphasize working with PLCs in a
safe and reliable way that extends
beyond textbook knowledge or selflearned knowledge
2. Focus training on the PLC products
that are actually used or will be
used in the facility in the future
To get more out of your PLC training investment, implement hands-on
training using the actual PLC programs and software that the maintenance technician will be working with
in the facility. Ensure that your personnel have the software, equipment
and encouragement to continue with
self-education. PLC Training CBT
(computer-based training) CDs are a
good way for employees to follow up
six months after the initial training.
Also consider providing technicians
Author
Don Fitchett is president
and founder of Business Industrial Network (BIN; 2
Cityplace Drive, Suite 200, St.
Louis, MO; Phone: 573-5475630; Email: bin95@bin95.
com; Web: www.bin95.com).
He is also a long-time active
member of the Association
for Facilities Engineering.
Before starting up BIN, an
industrial training company,
Fitchett spent over 20 years developing and delivering industrial training around the world.
He has worked for world-class companies like
Toyota and Dana Corp. Fitchett currently works
as editor-in-chief for Feed Forward Publications,
a subsidiary of BIN, and has authored books on
the topic of The True Cost of Downtime, as well
as published articles in journals on this subject.
a. Aim to implement a common PLC brand in all equipment to

standardize PLC types
b. Obtain descriptor copies of PLC programs from the original
equipment manufacturer
c. Select PLC 110-V control voltage with a line filter
d. Select PLCs with a backup EEPROM option for zero downtime in some failure modes
6. Regard the forcing of inputs and outputs on or off as a safety
issue
7. Do not force inputs and outputs on or off without a second
opinion and a clear understanding of the complete effects on
the PLC program
a. If forces are installed, remove them within 24 hours and
find a more permanent solution
b. Document all forces in software and a written log before
enabling them
8. Online programming can be a safety risk. The normal procedure is to change the program offline and then download to
the PLC
with simulation software and/or a

spare PLC off the shelf for practicing.
PLC policies and procedures
If policy and procedures are not written and enforced, employees may
eventually return to old unreliable
ways.
Maintenance management of
CPD-5 8/20/07 10:34 AM Page 1
PLCs is rarely included in these poli-
cies, which is as detrimental as writing

guidelines for the health of the entire
organizations body, and then leaving
out the brain of the operation. While
a complete PLC policy and procedure
manual is out of the scope of this article, a general procedure for PLC management is outlined in the box.
Edited by Kate Torzewski
The best way to heat and cool

the most corrosive materials.
Nothing controls
temperatures of
corrosives and high
purity materials better
than AMETEK fluoropolymer heat exchangers. Not
glass. Not silicon carbide
or graphite units. Available
with steel or non-metallic
shells, diameters from 3"
to 14" and metric designs,
AMETEK heat exchangers
include TEMA/ANSI nozzle and
end connections. To learn more
call (302) 456-4431 or visit:
www.ametekfpp.com
47-49 CHE 11-07.indd 49
49
10/26/07 5:46:27 PM
Garlock Sealing Technologies
Focus on
Pipes &
Fittings
Parker/Page International Hose
NewAge Industries
Make a leak-free seal,

even for irregular flanges
The proprietary Multi-Swell gasket
material (photo) is said to be the
worlds first self-loading, general-service gasket. The material creates its
own load when it comes into contact
with oil or water, which virtually
eliminates the most common cause
of gasket failure insufficient load.
The material performs equally well in
water or oil, does not degrade in contact with oils and adapts easily to all
types of flange designs, all at a cost
comparable to conventional gasket
material, says the firm. Twice as soft
as conventional gaskets, Multi-Swell
is easy to cut and readily conformable
even to irregular flanges. Garlock
Sealing Technologies, Palmyra, N.Y.
Replace copper plumbing lines
with a plastic that looks golden
FlowGuard Gold (photo) is the latest addition to this firms CTS CPVC
plumbing pipe product line. Available
in 1/2- through 2-in. dia., FlowGuard
Gold is said to excel in hot- and coldwater applications. Compared to copper plumbing pipe, the plastic tubing is more corrosion resistant, and
using reliable solvent-welding
joining offers a substantially lower
installed cost, says the manufacturer.
This product meets the requirements
of NSF Standards 14 and 61 for quality and health effects. Harvel Plastics, Inc., Easton, Pa.
50
Harvel Plastics
Micromold Products
Dip pipes that require less space

and reduce installation costs
Used to deliver or withdraw liquids
or gases to and from reactor vessels,
columns and storage tanks, this line
of steel dip pipes and spargers (photo)
is lined and jacketed with PTFE to
handle corrosive liquids. Units are
available that fit large nozzles without
the need for reducing flanges, which
means fewer joints, less headroom and
lower installation costs, says the manufacturer. The PTFE-sealing faces of
the flanges of Micromold dip pipes and
spargers are machined to a uniform
thickness and surface finish to ensure
the highest seal integrity. Micromold Products, Inc., Yonkers, N.Y.
50-52 CHE 11-07.indd 50
W.L. Gore & Associates
Many different applications are

served by this nylon tubing
Nylotube (photo) is stocked in both
semi-rigid and flexible grades, six
colors, and inches and metric sizes.
The nylon tubing offers low moisture
absorption (1.4% maximum at 73F),
an excellent resistance to flex fatigue,
and is resistant to corrosion, abrasion,
crushing cracking and brittleness.
Nylotube is suitable for many applications, including instrumentation,
chemical transfer, food-and-beverage
lines, compressed air, refrigerant and
cooling systems, and pneumatic controls. Sizes range from 1/8- to 1-in.
O.D. and 4- to 12-mm O.D. NewAge
Industries, Inc., Southampton, Pa.

10/25/07 7:33:30 PM
Envirosight
High Pressure Equipment
AdvantaPure
Asahi America
This tubing and related products

have passed the test
This firms RCTW (rubber covered
fluoropolymer hose) and PAGE-flex
SBF products (photo, p. 50) have been
certified to meet the requirements of
USP Class VI. Certification includes
stringent testing of materials to determine biocompatibility, toxicity and
extractables of product. For end users,
especially in the pharmaceutical and
food industries, purity, taste, smell,
color and extractables are critical characteristics. With USP Class VI certified
hose, the assurance of purity is absolute, says the firm. Parker/Page International Hose, Fort Worth, Tex.
Just one gasket type is suitable
for steel, plastic or glass flanges
Unaffected by even the most aggressive chemicals, Gore Universal Pipe
Gaskets (photo, p. 50) provide exceptional performance in three important
areas: seal reliability, conforming to
irregular surfaces, and protecting
flanges. They are engineered to deliver superior bolt-load retention, and
achieve superior creep resistance for
reliable sealing of steel piping flanges.
Moreover, these gaskets deliver the
lowest stress-to-seal in even the most
fragile plastic and glass-lined flanges,
says the firm. The gaskets are suitable for temperatures up to 600F and
ber
pressures up to 3,000 psi. W.L. Gore

& Associates, Inc., Elkton, Md.
For high-pressure plumbing,
consider these fittings
This new line of NPT valves and fittings (photo) is designed for safe and
easy plumbing. Made of high-tensile 316 stainless steel, the new pipe
connection valves are offered in both
two-way straight and two-way handle
body configurations. Sizes available
include 1/8, 1/4, 3/8, 1/2, 3/4 and 1 in.
Fittings are available as elbows, tees
and crosses to accommodate either
10,000 or 15,000 psi. High Pressure
Equipment Co., Erie, Pa.
Pinpoint problem areas of sewers with this sidewall scanner
DigiSewer digital visual sidewall
scanning (DVSS; photo) enhances the
speed and detail at which pipeline
inspection is performed. In a single
day, a DigiSewer-equipped video inspection system can scan extensive
networks of pipe at full speed. When
scanning is complete, a supervisor
rapidly analyzes these scans using a
freeware viewer, zooming in on areas
of interest, and making measurements
and annotations directly on the scan.
Envirosight, Randolph, N.J.
For very concentrated H2SO4,

use this plastic piping
Troubles with existing sulfuric acid
piping systems, such as pipeline damage, leaks, joint failures, chemical spillage and downtime, have been caused
by a decrease in availability of lowconcentration (93%) H2SO4 and the
switch by suppliers to 98+% H2SO4,
says this firm. Many facilities running PVDF pipe systems had assumed
there would be no issue with higher
concentration acid in their pipelines,
but had problems within 36 mo. after
changing to the higher concentration.
Sulfur trioxide a natural contaminant is the culprit of the failure. As
a result, only Halar (E-CTFE) is recommended for this application, claims
the manufacturer. Halar Ultra Proline
piping systems (photo) sprovide reliability and cost savings to municipal
water-treatment facilities. Asahi
America, Inc., Malden, Mass.
Keep components healthy with
this patented technology
Hose Track (photo) uses RFID technology and software to identify parts and
monitor on-going wear-related events,
such as cleaning cycles, the number
of batches processed, and other userdefined occurrences. It involves readwrite RFID tags and readers to provide
a solution for the critical job of process
component maintenance and replacement. In May, the manufacturer received a U.S. patent for this technology, developed for hose assemblies
that are used in the pharmaceutical,
food-and-beverage, biomedical, chemical and other high-purity applications.
AdvantaPure, Southampton, Pa.
Corrosives are no problem
for this piping system
Designed specifically to provide a noncorroding, safe system for the conveyance of aggressive exhaust gases and
fumes, this firm has introduced the
SYGEF PVDF (polyvinylidene fluoride) Exhaust Piping System (photo,
p. 52). The new system conforms to
FM 4910 standards (Cleanroom Materials Flammability Test Protocol), and
is suitable for the state-of-the-art 300mm semiconductor manufacturing
50-52 CHE 11-07.indd 51
51
10/25/07 7:34:04 PM
GF Piping Systems
Nylok
Focus
plants as well as in the chemical and
microelectronics markets. Constructed
of the highly inert, high-strength thermoplastic PVDF, the system will not
corrode or rust. The system is available
in pipe sizes from 2 1/2 in. through 16
in., and includes a variety of fittings,
reducers, fixed flanges, gaskets, seals
and throttle valves. GF Piping Systems, Tustin, Calif.
Stress cracking is less problematic for pipes of this plastic
In January, this firm launched an enhanced version of its Hostalen CRP
100 black high-density polyethylene
grade, which enables its customers to
produce pressure pipes with increased
resistance to slow crack propagation.
Tradenamed Hostalen CRP 100 Resist
CR black, the polymer has been developed for non-conventional pipe-installation methods, where a superior resistance to stress cracking is required,
says the firm. Basell Corp.,

Hoofddorp. Netherlands
A coating that protects threads
from weld sputtering
The Nycote coating process is a nonconductive, White Teflon PFA powder
coating that can be applied to threaded
fasteners (photo). The patented process provides guaranteed protection
against thread contamination from
electrodeposited paints, primers and
adhesion of weld spatter and eliminates the need to manually apply
and later remove caps, tape or plugs.
There is no need for slave bolts and
retaping, which can compromise quality and safety. Nycote also adds lubricity to fasteners and reduces torque
versus tension scatter, says the firm.
Nylok Corp., Macomb, Mich.
Advertise in the
Classified
Interested?
For more information on classified
advertising, please contact:
Helene Hicks
Tel:212.621.4958
Fax: 212.621.4976
email: hhicks@che.com
C L A S S I F I E D A DV E R T I S I N G
T H AT W O R K S
See how the piping system behaves with one program

Launched in August, PIPE-FLO Compressible 2007 software is a major upgrade to the desktop application for
designing and simulating the operation of steam and gas piping systems.
The new upgrade integrates the calculating power of the PIPE-FLO product line with its familiar design and
dynamic-simulation features, resulting in a total piping-system view. It
includes functionality improvements
that allow the user to better visualize,
quickly calculate, efficiently communicate and provide access to information in one, easy-to-use program, says
the firm. Engineered Software, Inc.,
Lacey, Washington
Gerald Ondrey
Statement of Ownership, Management, and Circulation (Requester Publications Only)

1. Publication Title: Chemical Engineering 2. Publication Number: 0009-2460
3. Filing Date: 10/1/2007 4. Issue Frequency: Monthly except twice in October 5. Number of
Issues Published Annually: 13 6. Annual Subscription Price $59. Complete Mailing Address
of Known Office of Publication: Access Intelligence, 4 Choke Cherry Road, 2nd Floor,
Rockville, MD 20850-4024 Contact: George Severine Telephone: 301-354-1706 8.
Complete Mailing Address of Headquarters or General Business Office of Publisher: Access
Intelligence, LLC, 4 Choke Cherry Road, 2nd Floor, Rockville, MD 20850-4024 9. Full
Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor:
Publisher: Nella Veldran, 4 Choke Cherry Road, 2nd Floor, Rockville, MD 20850-4024
Editor: Rebekkah Marshall, 4 Choke Cherry Road, 2nd Floor, Rockville, MD 20850-4024
Managing Editor: Dorthy Lozowski, 4 Choke Cherry Road, 2nd Floor, Rockville, MD
20850-402410. Owner if the publication is owned by a corporation, give the name and
address of the corporation immediately followed by the names and addresses of all
stockholders owning or holding 1 percent or more of the total amount of stock: Veronis
Suhler Stevenson, 350 Park Avenue, New York, NY 1002211. Known Bondholders,
Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total
Amount of Bonds, Mortgages, or other Securities: None 12. Non-profit organization: not
applicable. 13. Publication: Chemical Engineering 14. Issue Date for Circulation Data:
September 2007
15. Extent and Nature of Circulation:
Average No. of
Copies Each Issue
During Preceding
12 Months
67,743
No. Copies
of issue
Nearest to
Filing Date
69,423
a. Total Number of Copies (Net press run)

b. Legitimate Paid and/or Requested Distribution
(1) Individual Paid/Requested Mail Subscriptions
57,985
58,901
2) Copies Requested by Employers
0
0
(3) Sales Through Dealers and Carriers, Street Vendors
0
0
(4) Requested Copies Distributed by Other Mail Classes
0
0
c. Total Paid and/or Requested Circulation
57,985
58,901
d. Nonrequested Distribution (By Mail and Outside the Mail)
(1)Nonrequested Copies, Sample copies, Requests Over 3
years old, Requests induced by a Premium, Bulk Sales and
Requests including Associate Requests. Names obtained
from Business Directories, Lists, and other sources)
7,222
6,168
(2) Nonrequested Copies Distributed Through the USPS
by Other Classes of Mail
0
0
(3) Nonrequested Copies Distributed Outside the Mail
(Include Pickup Stands, Trade Shows, Showrooms,
and Other Sources)
571
4,000
e. Total Nonrequested Distribution
7,793
10,168
f. Total Distribution (Sum of 15c and 15e)
65,778
69,069
g. Copies not Distributed
1,965
354
h. Total
67,743
69,423
i. Percent Paid and/or Requested Circulation
88.2%
85.3%
16. Publication of Statement of Ownership for a Requester
Publication is required and will be printed in the November 2007 issue of this publication.
17. Signature of Owner: Don Pazour Date: 10/1/07
I certify that all information furnished on this form is true and complete. I understand that anyone who
furnished false or misleading information on this form or who omits material or information requested on the
form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including
civil penalties).
52
50-52 CHE 11-07.indd 52
10/30/07 6:27:04 PM
Solids Processing
Environmental
Manager
Managing Material Safety

Data Sheets in the Workplace
While regulatory agencies
outline requirements for
communicating chemical
hazards, the format of compliance
is up to the employer.
Software tools can be helpful aids
in meeting these requirements
Karen E. Lintz
Wercs Professional Services, LLC
o ensure the health and safety

of workers, the U.S. Occupational Safety and Health Administration (OSHA) adopted
the Hazard Communication Standard
(HCS) in 1983. Initially designed to
protect workers in the manufacturing
sector, the HCS was expanded in 1987
to cover all industries where workers
could be exposed to hazardous chemicals. This article gives an overview of
the OSHA requirements for material
safety data sheets (MSDSs) and describes ways to meet these requirements with automated software tools.
Hazard communication program
All manufacturers and importers of

chemicals are required to review the
known physical and health hazards
of the chemicals they make or import
to determine if they are hazardous.
This process is known as hazard assessment. The manufacturers and
importers must have a process for
collecting and assessing this information, and then generating MSDSs.
While OSHA only requires MSDSs for
chemicals that are hazardous according to its definition, these data sheets
are also often written for non-hazardous materials.
When the MSDSs have been developed, the manufacturer must make
Material safety
data sheets are
an essential part
of hazard communication programs
them available to downstream users

of the chemicals, including its own
employees, distributors and customers. A written hazard-communication
program is also required to share this
information with employees through
training and the use of MSDSs and
warning labels. The written program
must describe how the requirements
for labels, MSDSs and employee training are going to be met in the facility.
This hazard communication program is
key to meeting OSHAs requirements.
Employee training
Under the HCS, all employees have

the right to know about chemical hazards in the workplace, and how they
can protect themselves against both
the physical and health hazards associated with exposure. Employees
must know the identities of the hazardous chemicals in their workplace

and where they can find the MSDSs
for the chemicals.
The HCS dictates that employees
be trained at least once a year, but
additional training should also be
conducted whenever a new hazardous chemical is introduced into the
workplace. The training must include
educating employees in the proper
use of the hazardous chemicals. Both
the physical and health hazards of
the chemicals should be included, as
well as information on how employees
can protect themselves from exposure.
Employees need to know the physical
properties of the chemicals, how to detect a spill or release of the chemical,
and what measures to take if a spill
occurs.
53-55 CHE 11-07.indd 53
53
10/25/07 7:30:12 PM
Environmental Manager
Employee access to information
According to OSHA, all employees
must have direct access to MSDSs for
the hazardous chemicals that are in
their work areas during their normal
working hours. Employers must ensure that employees are provided with
an MSDS for every chemical to which
they may be exposed, and employees
must receive training on any new
chemicals before the chemicals are introduced into the workplace. MSDSs
may be provided to employees as paper
copies contained in centrally located
binders or through computerized systems. Alternatives to paper copies are
permitted, as long as employees have
immediate access to the MSDSs. Maintaining paper copies of MSDSs in a
back-up method to electronic systems
is often a good practice.
Information requirements
To ensure that employees can properly handle hazardous chemicals in

the workplace, the HCS requires that
each MSDS include information about
the chemical that will allow employees
to quickly identify the chemical, recognize the possible hazards of exposure,
and take precautions to protect themselves against exposure. The HCS is a
performance-oriented standard, which
means that OSHA provides very few
requirements for the format of MSDSs.
However, the HCS does specify that
MSDSs must be available in English, and must include the following
information:
The product name as it appears on
the container label: This allows employees to quickly locate the proper
MSDS for the chemical they are
handling
The names of all of the hazardous
chemicals in the product that are
present at a concentration of greater
than 1% (0.1% for carcinogens): Nonhazardous chemicals may also be
listed, but full disclosure of a products formulation is not required
The physical and chemical characteristics of the chemical, such as its
physical form, color, odor, flash point
and vapor pressure: To ensure safe
handling, employees must be able to
recognize how a product is supposed
to look and behave
The physical hazards of the product,
54
such as flammability and reactivity:

This information may be important
for proper handling, storage, and
disposal of a chemical
The known acute (immediate or
shortterm) and chronic (longterm)
health hazards of the chemical
The signs and symptoms of exposure: Some chemicals do not have
good warning properties, such as a
smell, so employees must be able to
recognize any expected health effects from overexposure to a hazardous chemical
Any medical conditions that may
be aggravated by exposure to the
chemical: Employees with pre-existing medical conditions may need
to take additional steps to ensure
their safety when working with a
chemical
The routes of exposure for the hazardous chemical: This information is
important when choosing the proper
personal protective equipment to be
worn while handling a hazardous
chemical. Severe irritants or chemicals that can be absorbed through
the skin may require specific gloves
or protective clothing, while products
that are respiratory hazards may
need special ventilation or respiratory protection for safe handling
The exposure limits for the hazardous chemical, including the OSHA
permissible exposure limit, the
ACGIH (American Conference of
Governmental Industrial Hygienists) threshold limit value (TLV),
or a recommended exposure limit
developed by the manufacturer of
the hazardous chemical: This information is critical to ensure that
employees are not overexposed to
hazardous chemicals during the
workday
The classification of the chemical as
a known or potential carcinogen by
OSHA, NTP (National Toxicology
Program), or IARC (International
Agency for Research on Cancer)
Precautions for safe handling and
use, including hygiene practices and
cleanup procedures
Appropriate engineering controls
and personal protective equipment
Emergency and first aid procedures
The date the MSDS was prepared
The name, address and telephone
number of the party responsible for

preparing the MSDS
The MSDS may also provide additional regulatory information for the
hazardous chemical. SARA (Superfund Amendments and Reauthorization Act) hazard classifications, CERCLA (Comprehensive Environmental
Response, Compensation and Liability Act) reportable quantities (RQs),
transportation information, global
inventory compliance, and environmental hazards or effects are often
included in MSDS. When these documents are written to the ANSI (American National Standards Institute)
standard guidelines, they will meet
OSHA requirements and provide the
user with additional helpful toxicology
and regulatory information.
Updating the MSDS
In the U.S., there is no specific timeframe requirement for updating

MSDSs. When the document is prepared, it must include the most upto-date information about the chemical hazards based on the available
scientific evidence at that time. If a
manufacturer becomes aware of new
significant information regarding a
chemicals hazards, the manufacturer
has three months to update its MSDS.
This updated version must be provided
to customers with the next shipments
of the hazardous chemical. To ensure
compliance with this requirement,
manufacturers must closely monitor
global chemical regulations as well as
new reports of adverse health or environmental effects associated with
chemical exposure.
MSDS management software
While there are no requirements for

generating MSDSs through specific
software, many companies utilize software tools or programming to produce
and manage their MSDSs.
Using dedicated MSDS-management software has several distinct
advantages over word processing: increased MSDS-production efficiency;
enhanced MSDS-language consistency; better formulation management; and ease of distribution.
Global market. In todays global
market, having a system that supports
alternate templates and languages to
53-55 CHE 11-07.indd 54
10/25/07 7:30:37 PM
meet the requirements for specific regions or countries is a must. All global
product information can be stored in
MSDS management software, allowing for the quick and easy production
of MSDSs for any country or region.
Rules or logic tools. Automated tools
can decrease the need for manual data
entry and manipulation. By using appropriate software, information can be
automatically entered into the MSDS
based on system rules or logic. This
not only increases the efficiency of
MSDS production but the consistency
of MSDS information as well.
Impact of regulatory changes. The
impact of changes in regulations can
be quickly determined through the
use of automated impact analyses
and update tools. These tools can ensure that all affected products are reviewed, and required changes are applied appropriately. These tools can be
configured to apply to local, regional,
state, federal and global changes, de-
pending on the needs of the user.

MSDS distribution tools. Automated MSDS distribution tools are
also a very useful part of an automated
system. MSDSs can be automatically
mailed, faxed, emailed, or sent to a
web viewer based on predetermined
criteria.
Through proper training, procedures,

and automated software tools, we can
ensure that our employees and customers always receive the most upto-date information for the chemicals
they use.
n

Edited by Dorothy Lozowski
Author
Looking forward
Requirements for MSDSs will continue to grow and change. New initiatives, regulations and health-effect
information make it necessary for regulatory professionals to continually be
on the lookout for anything that may
impact their MSDSs. New guidelines
or classification systems, such as the
Globally Harmonized System of Classification and Labeling of Chemicals
(GHS), will impact how we communicate and classify information. Regulatory professionals must keep abreast
of not only the OSHA requirements for
MSDSs, but also global requirements.
Karen Lintz is the director of regulatory services for

Wercs Professional Services
(WPS); (Phone (800) 572-6501
or (518) 640-9220; Email:
info@thewercs.com; Fax; (518)
640-9299), where she provides
regulatory guidance in support of software content and
implementation. Prior to this
position, Lintz was a regulatory specialist at GE Silicones. In earlier positions, Lintz followed patients in human clinical
cancer-treatment trials as a study coordinator at
the Cancer Center of Albany Medical Center, developed and reviewed clinical protocols and case
report forms as a data manager at Frontier Science and Technology Research Foundation, Inc.,
and worked as a product safety specialist at the
Carborundum & Advanced Materials Division of
BP Chemicals. Lintz holds a B.A. in biology from
Lycoming College and an M.A. in pharmacology,
toxicology and therapeutics from the State University of New York at Buffalo.
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email: clientservices@accessintel.com
53-55 CHE 11-07.indd 55
55
10/25/07 7:31:04 PM
Process Economics Program:

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Presenting an Unparalleled Resource

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The PEP Yearbook currently provides updated economics for over 1100 process
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www.sriconsulting.com/PEP
MENLO PARK
56 CHE 11-07.indd 56
HOUSTON
BEIJING
TOKYO
ZURICH
10/16/07 11:14:07 AM
Special Pumps Advertising Section
Flowserve
The Flowserve Durco Mark 3 ANSI process pump is renowned for
its reliability and durability in severe chemical service applications.
It is designed with several unique features that help improve
performance and reduce operating costs, including an exclusive
reverse vane impeller. This impeller provides benefits such as:
low, predictable, constant seal chamber pressure for reliable seal
performance; low NPSHR to mitigate damage from cavitation; rear
cover wear transfer that protects the casing from erosion; and 20-second in-shop impeller setting.
Additional pump features include: the SealSentry seal chambers; and the Mark 3A power end with
its external micrometer impeller adjustment. An optional ANSI 3A power end with a lifetime warranty
is also available. The Mark 3 ANSI handles flow rates to 1680 m3/h (7400 gpm) and heads to 215
m (700 ft). Temperatures can range from -75C (-100 F) to 370C (700F) and pressures to 27
bar (400 psi).
For more information about Flowserve, see their ad on Pages 32D-7, 32D-9
Gorman-Rupp
Pump for Chemicals
The Gorman-Rupp Company has released a Pumps for Chemicals brochure highlighting pumps and
related equipment for the chemical industry.
The brochure contains information on the entire line of chemical
duty pumps including; self-priming centrifugal, high efficiency,
straight centrifugal, submersible, portable engine driven, rotary gear
and air-driven diaphragm pumps. All designed for wastewater or
process applications. Gorman-Rupp also manufactures complete
pumping stations that include pumps, drives and controls.
Pumps are available in various materials of construction for abrasive
and corrosive applications.
The Gorman-Rupp Company has 75 years of pump manufacturing
experience and the leading distribution network in the world. When
you need a pump for handling tough chemical applications, think
Gorman-Rupp!
For more information aboutGorman-Rupp, see their ad on Page 7
57
57-58 CHE 11-07.indd 57 21

CE_NovPumpSection.indd
10/25/07 3:08:59
6:23:02 PM
PM
10/25/07
Special Pumps Advertising Section
Goulds Pumps
Goulds Offers Lined Magnetic Drive Pumps
ITT Goulds Pumps has an entire line of heavy duty, magnetically
driven, lined ANSI process pumps. The 3298 will handle the
caustic, corrosive fluids safely, reliably and at a minimum
operational cost. The 3298 is available in frame mounted,
close-coupled, vertical in-line and self priming configurations.
Liquid-end parts are lined with a thick layer of Tefzel (ETFE)
for universal corrosion resistance and an impenetrable barrier
against leakage. The 3298 meets the strictest EPA regulations under the Clean Air Act. Zero emissions
for a safe system and work environment. Efficiencies are equal to conventionally sealed ANSI pumps
and as high as 30% better than competitive metallic, mag drive pumps. The 3298 Series offers
capacities to 1,200 GPM (270m3/h), heads to 425 feet (129m) and temperature limits to
250F (121C).
For more information about Goulds Pumps, see their ad on Page 1
Wood Group ESP

Alternative Surface Pump Solutions
Pressure to reduce initial capital expenditures and the desire to lower increasing maintenance costs
as well as reduce environmental impact has encouraged many to evaluate alternative fluid handling
technologies for surface pump applications.
Building on down hole electric submersible pump technology,
the SPS Surface Pumping System has developed a reputation
as a low-maintenance, cost-effective alternative to vertical
turbine, split-case and positive displacement pumps in a variety
of industrial surface fluid-movement applications. These systems
feature a direct-drive, multistage centrifugal design ideally
suited for most high-pressure, low- to medium-volume and
environmentally sensitive applications.
A single SPS unit rated for 160 gpm at 3000 psi with a
400 HP motor installed in a Louisiana plant on washwater pump service.
Offering a low surface profile and quiet vibration-free operation,

SPS pumps can be electric, gas- or diesel-powered. They can typically handle up to 2000 gpm
(64,000 BFPD) and discharge pressures ranging up to 6000 psi. SPS technology has inherent
advantages such as low NPSH, lack of pulsation, product containment, volume and pressure flexibility,
and the lack of high-pressure packing glands that help operators eliminate costly maintenance
repairs, nuisance shutdowns, product leakage, piping stresses and man-hour consumption. They
are very flexible and can be easily modified to handle a variety of service requirements. Design
adjustments to such items as the seal assembly, elastomers and metallurgy are made routinely to
accommodate special applications.
For more information about Wood Group ESP, see their ad on Page 28
12560
58
CE_NovPumpSection.indd
57-58
CHE 11-07.indd 58 22
10/25/07 6:24:25
3:09:03 PM
PM
10/25/07
PRODUCT SHOWC ASE

High Pressure
Silencers
x
x
x
x
x
Simple yet effective diffuser

silencing
Suitable for high pressure, high
temperature steam and gas
Compact size and weight
Non Clogging
Minimum supporting requirement
Model
D800
Silencer
SEALS/GUARDS 2C AD-07
8/15/07
8:59 AM
Expect Engineering Excellence
"Loders Croklaan's new

Pulsair equipped state-of-the-art
Palm Oil Refinery Rotterdam,
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Mixing Solutions for

Multiple Tank
Configurations
Pulsair pneumatic mixers are
the undisputed leader in Process
Control Management. Our
systems are designed to operate on
minimal nitrogen, thus eliminating
temperature fluctuation and specific
gravity stratification in tanks. The
Pulsair System operates multiple
tanks exceeding one million
gallons each or more, with one
programmable controller, creating a
consistent viscosity every time.
Protect pressure or vacuum

instruments from clogging,
corrosion and damage.
Compact and Economical, Plast-O-Matic
Gauge Guards prevent dangerous leaks and
allow dependable instrument readings from
full vacuum to 250 psi.
PTFE or FKM
diaphragms.
PVC, Polypro or
PVDF bodies.
Available with
or without
gauges.
Gauge
Shields for
harsh environments.
For further information, contact

CU Services LLC
725 Parkview Cir, Elk Grove, IL 60007
Ph 847-439-2303 rcronfel@cuservices.net
www.cuservices.net
425.455.1263
800.582.7797
sales@pulsair.com
www.pulsair.com
PLAST-O-MATIC VALVES, INC.
CEDAR GROVE, NJ 07009

(973) 256-3000 Fax: (973) 256-4745
www.plastomatic.com info@plastomatic.com
Penn Separator Corp.
Automatic Condensate
Aftercoolers
Normally
used with a
blowdown
separator a
Penn Aftercooler can
also be used
alone in a
condensate
line going to drain where steam
is not present to automatically
cool the condensate to 140
deg. F to meet local requirements. They are available in 2
thru 8 sizes. An adjustable self
actuating valve senses the temperature and adds the correct
amount of cooling water.
P.O. Box 340

Brookville, PA
15825
Phone: 1-888-PENNSEP
(736-6737)
Fax: 814-849-4510
Email:
info@pennseparator.com
Web:
www.pennseparator.com/ce
59 CHE 11-07.indd 59
59
10/29/07 5:51:56 PM
Page
Intelligen Suite
The Market-Leading Engineering Suite for Modeling, Evaluation,

Scheduling, and Debottlenecking of Single & Multi-Product Facilities
SuperPro
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Use SuperPro Designer to model, evaluate, and
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Tracking of equipment occupancy

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Switch to SchedulePro to schedule, model,

and debottleneck multi-product facilities
Inventory tracking for raw materials,

intermediates, products, and wastes
SuperPro Designer is a comprehensive process simulator that facilitates modeling, cost analysis, debottlenecking, cycle time
reduction, and environmental impact assessment of biochemical, specialty chemical, pharmaceutical (bulk & fine), food, consumer
product, mineral processing, water purification, wastewater treatment, and related processes. Its development was initiated at the
Massachusetts Institute of Technology (MIT). SuperPro is already in use at more than 400 companies and 500 universities around
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

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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
60-65 CHE 11-07.indd 60
10/30/07 6:31:48 PM
s,
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Interfaces with many process simulator and physical property

packages either directly or via CAPE-OPEN.
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College Station, Texas 77845, USA
HTRI@HTRI.net
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60-65 Che 11-07.indd 61
61
10/30/07 6:32:23 Pm
New & Used Equipment

Process Filtration Equipment
JWI Filter presses with polypro recessed plates
Sizes available: 2, 3, 5, 12, 25, cu. ft.
Sparkler & Niagara horizontal plate filters,
Model 33D17, 18S23, 1824S, 3348S
Komline 1' x 12' SS Vac. Belt Filter
Nutsche filter, 10 gal, 316 SS, 35 psi
Stainless Steel ERTEL & STAR Filter presses
Star 18" diameter SS plates, 14 chamber, 45 sq. ft.
Netzsch 10 cu. ft. 630 mm, polypro plates
Several small Oberlin belt filters
Avery Filter Company, Westwood, NJ
Phone: 201-666-9664 Fax 201-666-3802
E-mail: larry@averyfilter.com
www.averyfilter.com
New ARRIVALS for FALL- BIOPHARM

50 sq. ft. Pellicon 2 Maxi Ultra Filtration System, Sanitary 316 S/S
500 liter Vertical Agitated BioPharm Pressure Vessel, 316L-S/S
125 liter Vertical BioPharm Reactor Body, 316L-S/S
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)
0.75 gal. Baker Perkins Jacketed Vacuum Sigma Blade Mixer, S/S (6)
2 CFM to 1600 CFM Stokes and Kinney Vacuum Pumps (75)
TOO Many Items to List..Please contact us for more info.
Website: WWW.HPEQUIP.COM
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60-65 Che 11-07.indd 62
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CONTROL
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The CUB is an electromechanical

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Some advantages of the CUB are:
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60-65 Che 11-07.indd 63
Ask about our complete line

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CHEMICAL ENGINEERING
DAL005073B
ABROWN
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CBI0004
Recruitment
Faculty Positions in
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at Ecole Polytechnique Fdrale de Lausanne (EPFL)
The School of Engineering at EPFL invites applications for a tenure-track faculty
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e-mail: hiring.stime@epfl.ch
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64
60-65 Che 11-07.indd 64
CBIJobs.com
engineering procurement fabrication construction
EOE
10/30/07 6:34:21 Pm

Process
Equipment Sale
Surplus assets include:
GEA Niro Kestner S.A. Titanium Desalination Plant

Krauss-Maffei Horizontal Peeler Centrifuges HZ
Flottweg Hastelloy Decanter Centrifuges
GEA Niro A/s Spray Drying Plants
Pfaudler-Balfour Glass Lined Reactors
Hastelloy C-22 & C-276 Reactors
Duplex Stainless Steel Reactors
316L Stainless Steel Reactors
Hastelloy Shell & Tube Heat Exchangers
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Thermal Oxidizers
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for more information tel: +44 (0) 870 7522977

or download the full catalogue at
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Filter Presses
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60-65 Che 11-07.indd 65
65
10/30/07 6:34:49 Pm
66-67 CHE 11-07.indd 66
10/31/07 3:42:32 PM
66-67 CHE 11-07.indd 67
10/31/07 3:43:31 PM
Directory of Chemical Producers:

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Plant-by-plant capacity data for more than 200 products including petrochemicals,
organic intermediates, inorganic chemicals, polymers and fibers
Annually updated directories for Canada, China, East Asia, Europe, India,
Mexico, Middle East, South & Central America, and United States
Smart Research. Smart Business.
www.sriconsulting.com/DCP
MENLO PARK
68 CHE 11-07.indd 68
HOUSTON
BEIJING
TOKYO
ZURICH
10/25/07 6:29:24 PM
Advertisers Index
Advertiser
Phone number
Page number
Reader Service #
Alfa Laval AB

11
* Alstom Power Incorporated 8
877-661-5509 adlinks.che.com/6901-10
Ametek
49
302-456-4431 adlinks.che.com/6901-27
Beijing Pharmasciences
Company, Limited
26
86-10-67877368

Advertiser
Phone number
Page number
Reader Service #
Itt Industries
Advertiser
Phone number
Page number
Reader Service #
1 Pompetravaini Spa
1-800-734-7867

Haver & Boecker
32I-6
49-25 22-30 0

Heinkel Usa
32D-4
856-467-3399 adlinks.che.com/6901-29
Honeywell Process SECOND

Solutions
COVER
Phone number
Page number
Reader Service #
32I-7 * Sulzer Chemtech Ag
39-0331-889000

Rembe Gmbh Safety

+ Control
32D-11, 32I-10
704-443-7022 adlinks.che.com/6901-37
Robert-james Sales,
Incorporated
Advertiser
19
41 52 262 50 28

The Western States

Machine Company
32D-12
513-863-4758

32D-6 * Tlv Corporation
800-666-0088 adlinks.che.com/6901-31
Robuschi & C. s.p.a.
32I-5
17
704-597-9070

1-877-466-3993
23
Veolia Water
THIRD COVER
39-0521-274911

41 21 989 21 21



adlinks.che.com/6901-20 * Larox OY
6
9

adlinks.che.com/6901-07 Spectro Analytical Instruments Veolia Environment
Bioengineering Ag
21

Gmbh & Co.kg
32I-8

Load Controls, Inc.
32D-11
49-2821-892-2102
Witzenmann Gmbh
32I-3
888-600-3247
Burgmann
32I-9

49-7231-581-0

49/8171/23-0 adlinks.che.com/6901-41

Sri Consulting
30
* Lubrizol Corporation
32D-5
CEJN Industrial

Wood Group Esp
28
1-888-234-2436
Corporation
32D-8
281-492-5160 adlinks.che.com/6901-24
Sri Consulting
56

1-847-263-7200

Yamatake
FOURTH
Mehrer Kompressoren
27

Sub-one Technology
2
49
(0)
7433/26
05
0
Corporation
COVER
* Charles Ross & Son Co.
12
925-924-1020 adlinks.che.com/6901-05

888-262-4639 adlinks.che.com/6901-03
1-800-243-ROSS

Biazzi Sa-switzerland
See bottom of next page for advertising sales representatives' contact information
Check-all Valve Manufacturing

Company
32D-10
515-224-2301 adlinks.che.com/6901-35
Coade Engineering
Software
22
Conbraco Industries,
Incorporated
15
1-281-890-4566

1-704-841-6000

* Dresser Roots
31
877-363-7668 adlinks.che.com/6901-26
Emerson Process
Management
17
* Endress + Hauser
Fike Corporation
10
1-866-758-6004

Fisher-klosterman,
Incoroprated
32D-3
502-572-4000 adlinks.che.com/6901-28
Flowserve Corporation 32D-7
Flowserve Corporation 32D-9

Advertisers
Product Showcase. . . . . . . . . . . 59
Computer Software . . . . . . . . . 60-61
Consulting . . . . . . . . . . . . . . . . . 63
Equipment, Used or
Surplus New for Sale. . . . 62-63, 65
Recruitment. . . . . . . . . . . . . . 64-65
Service . . . . . . . . . . . . . . . . . . . 65
888-ENDRESS

Classified Index - November 2007 (212) 621-4958 Fax: (212) 621-4976
Send Advertisements and Box replies to: Helene Hicks, Chemical Engineering, 110 William St., 11th Floor, New York, NY 10038
Fluid Metering, Inc.
516-922-6050 adlinks.che.com/6901-09
Franken Filtertenchnik Kg 24
49 2233 974 40-0

* GEA Jet Pumps Gmbh 32I-11
49 7243-705-0

* Gorman Rupp Company
419-755-1011 adlinks.che.com/6901-08
Goulds Pumps,
International Section
* Additional information in
2006 Buyers Guide
Advertiser
Phone number
Page number
Reader Service #
3Di Equipment Ltd.
65
+44 (0) 870 7522977

Applied e-Simulators
Software
61
Avery Filter Co.
62
Bag Supply Company
62
CB&I
64
509-967-5730

201-666-9664

800-722-5790


CU Services LLC
59
847-439-2303

Custom Metalcraft, Inc.
63
417-862-0707

EcReCon, Inc.
63
EPFL
64
856-299-4500


Advertiser
Phone number
Page number
Reader Service #
EquipNet Inc.
62
Flowphase Engineering
Software
61
FPC National
65
888-371-6555

403-250-7522

212-302-1141

General Spray/CPV
Drying Services, Inc.
65
908-353-2477

H&P Equipment Co., Inc.
62
973-335-9770

Heat Transfer Research, Inc. 61

979-690-5050

Heyl & Patterson
63
412-788-9810

HFP Acoustical Consultants 63
888-789-9400

Advertiser
Phone number
Page number
Reader Service #
Outotec Research Oy
61
Paul Mueller Company
59
Penn Separator Corp.
59
Plast-O-Matic Valves, Inc.
59
Pulsair Systems
59
Readco, Kurimoto, LLC
59
Ross, Charles & Son Co.
63
Sunrise Systems, Inc.
61
Wabash Power
Equipment Co.
62
Water Works
65
+358-20-529 211

800-683-5537

888-736-6737

973-256-3000

800-582-7797

800-395-4959

800-243-7677

+44 1223 441311

Hockmeyer
Equipment Corp.
63
Indeck
65
Intelligen, Inc.
60
The Western States

Machine Co.
63
KnightHawk Engineering
63
Xchanger, Inc.
63
252-338-4705

847-541-8300

908-654-0088

281-282-9200

847-541-5600

800-232-9334

513-863-4758

952-933-2559

22_CHE_110107_AD_IND_RS.indd 69
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10/31/07 5:13:39 PM
New Product Information

November 2007
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
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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
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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
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40 Drying Equipment
41 Filtration/Separation Equipment
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43 Instrumentation & Control Systems
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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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22_CHE_110107_AD_IND_RS.indd 70
10/31/07 5:14:04 PM
Economic Indicators
Business News
Plant Watch
BASF inaugurates two new
plants in Texas
October 8, 2007 BASF inaugurated
two new manufacturing plants at its
site in Freeport,Tex.The polyamide
production line, which replaces a facility
in Enka, N.C., has a capacity of 120,000
m.t./yr.The new superabsorbentpolymers (SAP) manufacturing plant
(photo) has a capacity of 180,000
m.t./yr and replaces existing facilities
in Aberdeen, Miss. and Portsmouth,Va.
These two plants are supplied with raw
materials, caprolactam and acrylic acid
respectively, from other BASF plants at
the Freeport site.
Basells technology is licensed for
a polypropylene plant
October 8, 2007 Qatar Petroleum
has selected Basells Spheripol
technology for a new 700,000-ton/yr
polypropylene plant that will be built in
Mesaieed, Qatar, as part of the Qatar
Petrochemical Complex project.The
unit will be operated by a joint venture
between Qatar Petroleum and Honam
Petrochemical of Korea. Startup is
expected in 2011.
Metso to supply minerals
processing plant to Gradir
October 2, 2007 Metso Minerals will
supply a minerals processing plant to
Gradir Montenegro, a supplier of lead
and zinc concentrate, to be located at its
mine in Montenegro.The delivery will be
completed during the 2nd Q of 2008.The
approximately 7-million order includes
equipment for crushing, screening,
grinding, dense medium separation,
flotation, filtration and tailings treatment.
The mines capacity is estimated to rise
from 170,000 m.t./yr to 500,000 m.t./yr of
ore once the expansion is complete.
Evonik is increasing its alkoxide
production capacity
October 2, 2007 Evonik Industries AG
will build an alkoxide production facility at
its Mobile, Ala. site.The plant, designed for
a capacity of 60,000 m.t./yr, is expected
to come onstream in early 2009. A second
facility in Brazil is scheduled to start
operation the following year.
A $105-million investment is planned

for biofuel and electricity complexes
October 1, 2007 Dynamotive Energy
Systems Corp. and its subsidiary
Dynamotive Latinoamericana S.A.,
announced that they have submitted
documents detailing plans to invest
approximately $105 million to develop
two self-contained biofuel-to-electricity
complexes in Corrientes, Argentina. Each
complex will be comprised of a 15.7-MW
electricity-generating station powered
by the majority of the fuel output of two
200-ton/d modular plants producing
biofuel from wood waste and residues
from nearby forests and other biomass
residue. Development and construction
of the complexes, which are expected to
be fully operational late next year, will be
implemented by Dynamotive, jointly with
Tecna, a major Argentine engineering
firm.
ChemPro Group designs and fabricates
modular ethanol plant
September 29, 2007 The ChemPro
Group, LLC announced that the company
has contracted with Golden Triangle
Energy of Craig, Mo., to design and build
a modular, distillation dehydration plant
for the production of high-quality ethanol
from corn-based fermentation feedstock.
The facility will be a multi-tower distillation
plant consisting of free-standing distillation
columns, seven process modules and
a stair module to connect them. Plant
assembly will begin in 2007, with startup
scheduled for the 1st Q of 2008.
SAFC to expand high-potency API
fermentation capabilities
September 26, 2008 SAFC, a member of
the Sigma-Aldrich Group, has announced
a $29-million investment to significantly
expand its drug substance capabilities
in high-potency biologics at its facility
in Jerusalem.The site enhancement will
enable SAFC Pharma to provide process
development and cGMP manufacturing
to customers requiring large-scale,
high-potency, toxic or hazardous drug
substances. The expansion is scheduled
for completion in the 1st Q of 2009 and
is expected to broaden capabilities to
complement the multi-step, organicsynthesis flagship facility at the companys
Madison, Wis. location.
This facility is the new superabsorbent polymer (SAP) plant

at BASFs Freeport, Tex. site
Mergers and
Acquisitions
Ineos Silicas and PQ
Corp. combine
October 11, 2007 Ineos and the Carlyle
Group have reached an agreement in
which the PQ Corp., the specialty chemical
company acquired in July 2007 by The
Carlyle Group, will combine with Ineos
Silicas. Under terms of the proposed
agreement,The Carlyle Group will have
approximately 60% share and Ineos
approximately 40%. The financial terms are
not disclosed. The combined business will
become a global producer of specialty
inorganic chemicals, catalysts and
engineered glass products with annual
sales revenue of $1 billion.
Lanxess completes two
portfolio adjustments
October 2, 2007 The former Lustran
Polymers business unit of Lanxess has
become part of Ineos ABS, a newly formed
joint venture with British chemicals group
Ineos. Lanxess initially holds a 49% financial
interest in the joint venture, while the
operating business is run by Ineos.This
minority interest held by Lanxess will also
be acquired by Ineos in two years time as
agreed. Meanwhile, Lanxess has divested
its wholly owned subsidiary Borchers GmbH,
which specializes in additives for coatings,
emulsion paints and printing inks, to the OM
Group (OMG) in the U.S.
Haldor Topse acquires Saipems
shares in Haldor Topse A/S
September 27, 2007 Dr. Haldor Topse
now holds all the shares in Haldor Topse
after acquiring Saipems 50% share for
a consideration of 340 million in cash.
Saipem is the owner of Snamprogetti, which
originally invested in Haldor Topse A/S
alongside Dr. Haldor Topse in 1972. Haldor
Topse A/S will continue its current focus
on providing innovative research-based
solutions for catalysis and related process
technology with global operations and
n
headquarters in Copenhagen.

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

November 2007; VOL. 114; NO. 12
Chemical Engineering copyright @ 2007 (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: 212-6214674, 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
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P.O. Box 1632, Windsor, ON N9A7C9.
For more Economic Indicators, See Next Page
71-72 CHE 11-07.indd 71
71
10/29/07 5:48:28 PM
Economic Indicators
2006
2007
download the cepci two weeks sooner at www.che.com/pindex
CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI)

(1957-59 = 100)
Aug. '07
Prelim.
531.5
632.9
602.9
601.7
747.4
428.6
836.1
434.5
669.9
317.2
478.5
356.4
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
Jul. '07
Final
533.7
636.4
609.4
603.5
746.0
430.6
829.8
435.4
678.4
316.9
478.2
356.5
Aug. '06
Final
510.0
602.3
560.9
556.2
731.7
437.2
788.3
414.2
637.7
312.9
475.2
351.9
540
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
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)
Index of industrial activity (1992 = 100)
Hourly earnings index, chemical & allied products (1992 = 100)
Productivity index, chemicals & allied products (1992 = 100)
Sep. '07
Aug. '07
Sep. '07
Oct. '07
Sep. '07
Sep. 22, '07
Sep. '07
Sep. '07
111
CPI OUTPUT INDEX (2000 = 100)
1760
= 109.6 Aug. '07

= 1,613.6
Jul. '07
= 82.7 Aug. '07
= 749.0 Sep. '07
= 227.7 Aug. '07
= 311.4 Sep. 15, '07
= 142.8 Aug. '07
= 133.5 Aug. '07
CPI OUTPUT VALUE ($ Billions)
85
83
105
1600
81
102
1520
79
99
1440
77
A S O N D
=
=
=
=
=
=
=
=
109.5 Sep. '06 =

1,656.3 Aug. '06 =
82.8 Sep. '06 =
745.4 Oct. '06 =
233.3 Sep. '06 =
310.5 Sep. 23, '06 =
143.7 Sep. '06 =
132.3 Sep. '06 =
109.3
1,686.9
83.4
733.8
216.4
284.8
141.8
130.2
CPI OPERATING RATE (%)
75
1360
J A S O N D
YEAR AGO
= 109.4
Jul. '07
= 1,653.8 Jun. '07
=
82.7
Jul. '07
= 749.4 Aug. '07
= 222.8
Jul. '07
= 311.6 Sep. 8, '07
= 142.4
Jul. '07
= 132.0
Jul. '07
1680
J F M A M J
F M A M J
PREVIOUS
108
96
J F M A M J
J A S O N D
J F M A M J
J A S O N D
Current business indicators provided by DRI-WEFA, Lexington, Mass.
the Online CEPCI
MARSHALL & SWIFT EQUIPMENT COST INDEX

(1926 = 100)
3rd Q
2007
2nd Q
2007
1st Q
2007
M & S Index
1,393.0
1,383.6
1,362.7
Process industries, average 1,445.6
1,433.5
1,410.0
Cement
1,427.5
1,417.5
1,398.8
Chemicals
1,421.0
1,408.8
1,384.9
Clay products
1,408.8
1,400.4
1,378.1
Glass
1,341.8
1,331.3
1,309.5
Paint
1,451.2
1,440.2
1,414.2
Paper
1,364.0
1,354.0
1,331.6
Petroleum products
1,536.2
1,521.0
1,497.9
Rubber
1,494.8
1,486.7
1,463.1
Related industries

Electrical power
1,359.0
1,340.7
1,319.5
Mining, milling
1,453.2
1,442.7
1,427.7
Refrigeration
1,691.7
1,679.3
1,648.2
Steam power
1,407.4
1,394.2
1,369.1
4th Q 3rd Q
2006 2006
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
1,333.4
1,378.3
1,368.4
1,353.9
1,349.1
1,280.6
1,384.8
1,308.4
1,460.4
1,428.4
1,310.1
1,413.5
1,638.5
1,359.8
1,284.4
1,402.1
1,613.3
1,334.7
Annual Index:

72
1999 = 1,068.3
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
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/pindex
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
71-72 CHE 11-07.indd 72
10/29/07 5:48:30 PM
Creating
Water
Solutions
By-Product Recovery
Evaporation-Crystallization
Residuals Management
Process Water Treatment
Wastewater Treatment
With Proven Technologies and Local Service Organizations in more than 50 countries,
Veolia Water provides the Chemical Industry a Total Service Solution.
From packaged plants to turnkey installations and long-term operating services, Veolia Water offers
cost effective solutions for facility expansions, greenfield sites and plant upgrades.
Water, our business for 150 years
Please contact us at:

industries@veoliawater.com
http://chemicals.veoliawater.com/
PARIMAGE
Partnering with you on all your Water and Wastewater requirements.
10/15/07 12:30:28 PM
10/15/07 12:34:20 PM

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