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The Heat Transfer Data Book II

Fundamental heat transfer and application know-how
291 pages with numerous tables and pictures. Delivered as a PDF.
The Heat Transfer Databook II -Fundamental heat transfer and application know-how – is a valuable reference in all work and research in heat transfer engineering. The manual provides information and discussions on basic heat transfer, sensible heat transfer, condensing heat transfer, Trufin tubes in air-cool heat exchangers, and Trufin tubes in boiling heat transfer.
Preview the book here: http://www.wieland-thermalsolutions.de/databook2/
Chapters Include:
CHAPTER 1 – BASIC HEAT TRANSFER
CHAPTER 2 – SENSIBLE HEAT TRANSFER
CHAPTER 3 – CONDENSING HEAT TRANSFER
CHAPTER 4 – TRUFIN TUBES IN AIR-COOL HEAT EXCHANGERS
CHAPTER 5 – TRUFIN TUBES IN BOILING HEAT TRANSFER

Please contact Sarah Garwood at [email protected] for group or student pricing.

Fundamentals of Crystallization, Evaporation, Drying and Milling

This Chemical Engineering Guidebook features a collection of tutorial-style engineering articles, to guide process engineers on the proper selection, design, operation and maintenance of systems that are used to carry our crystallization and many related unit operations.
Crystallization is widely used in chemical process industries (CPI) facilities for two main purposes — to produce a given product in crystalline form, and to separate and purify phases in a larger chemical process. It is one of the most challenging unit operations, and as such, many problems can arise during scaleup and operation.
This PDF guidebook includes engineering articles and factsheets related to crystallization, drying, milling, granulation and other forms or particle-size reduction, bulk-solids transport and more.
Several articles focus on state-of-the-art vacuum processing and vacuum drying, while others focus on nitrogen inerting and other ways to ensure safety during crystallization. These practical, how-to articles were originally published in Chemical Engineering magazine, between 2010 and 2018.
149 Pages. Delivered in a PDF format.
Articles Include:
Crystallization
Hansen Solubility Parameters (HSP)
Spray Drying Parameters
Challenges of Drying Sticky Wastewater SludgeIn wastewater-sludge drying and dewatering operations, many issues arise from the sticky properties of the sludge.
Particle-Size Reduction
Vacuum Drying: Basics and ApplicationVacuum drying can be a useful tool for solid products that are heat-sensitive. Here are some guidelines for the selection and use of various types of vacuum dryers
Wastewater Sludge Centrifugation Before DryingThe decanter centrifuge is an important piece of equipment for sludge volume reduction prior to thermal drying. Understanding centrifuge operation helps manage drying energy costs
Increase Profits in Size-Reduction PlantsMaterial- and energy-balance models can help to identify potential opportunities
Characterize Bulk Solids to Ensure Smooth FlowTo minimize problems associated with handling all types of bulk solids, engineers must adopt a systematic approach to characterizing the flow and mechanical properties of the materials under a variety of operating conditions
The Benefits Of Two-Stage DryingCircular fluidized-bed dryers can boost the capacity, energy efficiency and product quality when used in conjunction with other primary dryers
Advances in Pin Mill TechnologyImprovements provide finer grinding at lower energy costs compared to air-swept classifying mills that have long reigned supreme in particle-size-reduction efforts
Batch Drying With Vacuum Contact DryersDrying is a demanding unit operation where solvents need to be removed without altering product chemistry. Vacuum dryers are essential pieces of equipment for accomplishing this task
Optimizing Analysis for Spray-DryingPrecise control over spray-drying processes can be enabled by modern measurement approaches that provide information on particle size and shape in realtime
Agglomeration and Granulation
Control Strategies Based On Realtime Particle Size AnalysisPractical experience illustrates how to achieve better process control
Adiabatic-Temperature Rise: An Awkward Calculation Made SimpleHow to estimate a final temperature after a reaction
A Clearer View of CrystallizersImproved understanding of crystallizer equipment and operation can aid purification efforts in the CPI
Biosludge Drying: System Design Schemes for the Sticky PhaseDrying biosludge from wastewater-treatment plants is complicated by the “sticky phase,” making the practice more of an art than a science. Discussed here are efforts to define the beginning and endpoints of this phase analytically
Guarding Against Fires and Explosions Caused by Self-HeatingThe two experimental methods presented here can be used to quantify powder self-heating hazards in layer and bulk conditions in industrial processes
Prevent Combustible Dust Explosions with N2 InertingTargeted use of blanketing with inert gas offers an effective strategy for preventing combustible dust explosions in CPI facilities
A Primer on Spray DryingAn understanding of the basic information presented here will help you produce powdered products with desired characteristics, while operating the drying plant safely and with minimum energy
Selecting theProper Mill for Your ProductUnderstanding breakage behavior is crucial in mills
Heat Transfer in Wiped Film EvaporatorsSimulations demonstrate the complex, changing properties of materials within the evaporator. Such information can help in both designing and selecting the proper evaporator
Confronting Crystallization IssuesReliable information about industrial crystallization can be difficult to find and to apply to new situations. The work process outlined here will help engineers approach crystallization challenges
Industrial Crystallization for the CPIThis overview presents the traditional and emerging types of continuous crystallizers
Reduce Hazards in Process Vacuum SystemsReduce explosion risks, and chemical and physical hazards, to ensure safer operation of vacuum pumps and related systems
MSMPR Crystallization Equipment
An Overview of Vacuum System DesignThe design of vacuum systems deserves careful attention — there are multiple facets that affect efficiency, operability and cost
Vacuum Systems: Recommendations for Safe OperationFollow this guidance to ensure that steam ejector systems, mechanical vacuum pumps and integrated vacuum systems are designed, operated and maintained to ensure process safety
Thin-Film Drying Offers Deep BenefitsThis continuous drying technology is especially safe and flexible, and offers many benefits, including low operating costs, low space requirements and high specific-evaporation capacity

MINIMIZING FOULING AND CORROSION: Equipment Operation and Troubleshooting- Volume One

Corrosion and fouling can wreak havoc in many chemical process operations, and can negatively impact process operations, depress chemical-conversion rates and product yield, reduce energy efficiency and incur excess costs associated with maintenance and repairs. Meanwhile, corrosion-related damage, and uncontrolled fouling or buildup in process equipment can lead to unscheduled downtime for maintenance, and in extreme cases, catastrophic failure of process equipment. All of this can create safety issues for plant personnel and neighboring communities, and reduce the overall profitability of the process.
This Chemical Engineering Guidebook contains practical engineering articles related to corrosion-related issues in specific types of equipment. The articles were originally published in Chemical Engineering from 2010 to 2018. Several articles provide practical guidance for managing and monitoring corrosion in pressure vessels and reactors, heaters, boilers, pumps, condensers, gas turbines, flares and more. Others focus on fouling and corrosion issues in aboveground and buried piping and storage tanks.
This guidebook is 198 and delivered in a PDF format.
Topics include:
Column Revamps: From Outside to Inside
• Some of the many things to consider for this complex task are presented here
Microreactors: Lessons Learned From Industrial Applications
• Implementing microreactors in chemical production is quite a challenge. How these challenges can be met is described here
Steam Concepts
Heat Exchanger Standards for Shelland- Tube Equipment
• Reliable operation of shell-and-tube heat exchangers begins with an appropriate standard. This article provides an overview of those that are applicable
Crossflow Membrane Filtration Essentials
• Several aspects of crossflow membrane filtration, including process design, equipment selection and control, are detailed here
Gas-Phase Filtration Media Properties: What to Know
• There are many physical properties that can impact the ultimate performance of adsorbent media in gas-phase filtration applications
Thermowell Installation
Polymer-based Piping
Controlling Membrane Fouling
Wet Scrubbers
Point-Level Switches for Safety Systems
• Industries that manufacture or store potentially hazardous materials need to employ point-level switches to protect people and the environment from spills
Design Underground Piping for Safety
• Buried systems bear a number of unique risks and require special considerations, including those related to soil characteristics and seismic loads
Inspecting Underground Piping
• First consider noninvasive methods to determine where excavation is — and isn’t — necessary
Flare Consolidation Considerations
• Consolidating multiple flares can help mitigate emissions and maintenance
Thermal Design Guidelines for Optimizing Shell-and-Tube Heat Exchangers
• Ensuring optimal performance of shell-and-tube heat exchangers requires knowledge of the controlling fluid, correct exchanger geometry and configuration, as well as proper fluid placement
Superheater Problems in Steam Generators
• Knowing the features of a good boiler will prevent problems associated with a poor design
Pressurized Piping: Sampling Steam and Water
• Without proper systems, analysis of steam and water chemistry can provide erroneous results —with costly implications
Flooded Condenser Controls: Principles and Troubleshooting
• Flooded condensers are the prime tower pressure-control methods for total condensers that generate only liquid products, and although these control methods can be troublesome, a good understanding of their principles will help achieve improved, trouble-free operations
Enclosed Combustion Equipment and Technology
• A thorough understanding of enclosed combustion technologies will help engineers to select the proper equipment to balance emissions-control performance with efficiency, costs and complexity
Operating Strategies for Gas Dehydration Units
• The presence of certain contaminants can wreak havoc on gas dehydration systems and other similar separation processes, but there are design measures that can help to minimize the issues caused by these substances
The Shotgun Approach
• Removal of Fouling Deposits on heat transfer surfaces in Coal-Fired Process Heaters & Boilers
Gas Turbines: Design and Operating Considerations
• Follow these engineering recommendations to improve gas turbine operation and performance while reducing operating costs
Filtration and Separation During Chemical Process Operations: Avoid Common Errors
• The seven commonly made mistakes discussed here often lead to poor filtration and separation performance and many associated problems
An Up-Close Look at Electropositive Filtration
• Electropositive filters take advantage of surface-charge effects to filter nanometer-sized particles. Provided here is an overview of how they work and where they can be used
Getting the Most from Severe Service Valves
• Severe service valves (SSVs) differ from general purpose valves in important ways. Presented here is guidance on how to increase service life, reduce costs and improve safety and environmental performance of SSVs
Implementing a Corrosion-Under-Insulation Program
• CPI facilities need to put in place a systematic program for preventing and mitigating corrosion under insulation
Rotating Machinery: What You Should Know About Operational Problems
• Follow this guidance to improve the operation, safety and reliability of rotating machinery in chemical process plants
Shell-and-Tube Heat Exchangers: The Design Cycle
• Following this step-by-step approach will ensure that the heat exchanger will perform as required when finally fabricated
Piping-System Leak Detection and Monitoring for the CPI
• Eliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design
Unlocking the Secrets of Plate-and-Frame Heat Exchangers
• An understanding of the design, sizing, specification and installation of plate-and-frame heat exchangers is necessary to evaluate vendors’ proposed designs
Reliable Operation and Sealing of Agitators
• Mechanical seals, as required by most vessel agitators, are systems sufficiently complex to warrant a good understanding by engineers and appropriate training for operators
Piping Design for Potentially Lethal Chemicals
• Integrity and reliability are critical for piping and equipment that handle chemicals with extreme health hazards
Optimizing Flare Operation Through Proper Design
• Flare problems are often caused by the seal systems that are designed to control air ingress. Follow these troubleshooting guidelines to improve design and ensure safe, reliable flare operation
Heat-Transfer Fluid Selection
Magnetically Driven Pumps: An overview
• Understanding sealless pump technologies and their potential applications

Managing Air Pollution: Eye on Fugitive Emissions and Dust Explosions- Vol 1

This Chemical Engineering guidebook contains tutorial-style engineering and “Facts at Your Fingertips” topics. The collection of practical, how-to articles provides engineering recommendations for minimizing fugitive emissions from valves, pumps, tanks and piping systems through proper equipment selection and use of appropriate seals and gaskets, as well as appropriate operations and maintenance strategies and monitoring techniques. Several articles focus on reducing the risk of potential dust explosions — a critical safety aspect for chemical process operations handling fine powders and other bulk solids. As a bonus, this guidebook also includes information that discuss best practices for managing and modernizing plant revamps and capital-intensive projects.

These articles were originally published between 2010 through 2019. It is the first of a 2 part series; Volume 2 — entitled “Managing Air Pollution — Volume 2: Eye on Combustion and High-Temperature Operations” — which is sold separately.

Delivered in a PDF, 220 pages.

Articles include:

Prevent Product Release with Pressure Protection Systems – 4
Closing off pressure upstream can minimize the need for pressure-relief systems to open, avoiding product waste and possible environmental damage

Key Considerations for the Use of Portable Gas Detectors- 8
Recent advances in gas-monitoring technologies can greatly increase worker connectivity and safety

Air-Pollution Control: Assessing the Options -11
Compliance with air-pollution regulations requires ongoing effort. Follow these recommendations to assess competing options and optimize system design while minimizing cost and risk

Controlling Dust through Pelletizing -20
Tumble-growth agglomeration can reduce dust in solids-handling processes. Here’s how it works

Designing Atmospheric Storage Tanks -25
Insights into the basics of process design of atmospheric storage tanks and an example of how to prepare a process datasheet are presented here

Dust Hazards -31

Activated Carbon -32

Clearing the Air About Respiratory Protection -33
Learn the basics about selection and regulatory compliance for these potentially life-saving devices

Common Mistakes When Conducting a HAZOP and How to Avoid Them- 39
An important part of ensuring the success of a HAZOP study is to understand the errors that can cause the team to lose focus

Chemical Process Plants: Plan for Revamps -44
Follow this guidance to make the most of engineering upgrades that are designed to improve plant operations or boost throughput capacity

Recent Air Regulations: Impact on Turnaround Vapor Deinventory Strategies- 50
With the onset of new environmental regulations, turnaround teams must look to temporary vapor-control strategies to ensure compliance during non-routine operations

Flow Measurement in Large Lines, Ducts and Stacks- 56

Controlling SO2 Without Corroding the Bottom Line- 57
Mist eliminators in wet scrubbers comprise a large portion of system operating costs. Consider these material selection and replacement criteria to curb chronic maintenance requirements

Cost Engineering: Equipment Purchase Costs- 65
A methodolody and examples for estimating equipment costs are presented

Dust Control in the Chemical Processing Industries- 68
The prevention of dust hazards in the CPI is integral to process-safety management — wide-reaching mitigation schemes must be implemented

Project Optimization Through Engineering- 72
Follow these practical recommendations to reduce capital outlay and operating costs, deliver shorter schedules and improve design quality

Things You Need to Know Before Using an Explosion-Protection Technique- 80
Understanding the different classification methods is necessary to better select the explosion-protection techniques that will be used

Activated Carbon: Fundamentals and New Applications- 85
Activated carbon sorbents are important tools in water purification and air-pollution control. This article provides information on the fundamentals of this diverse sorbent and on new applications for which it is being employed

Rupture Discs: Effectively Minimize Leaks and Emissions- 94
When installing rupture discs, there are several mechanical and operational considerations for reducing the likelihood of leaks and fugitive emissions

Containing Fugitive Emission- 99
Practical ways to seal valve stems and prevent unwanted emissions

Measuring Exposures to Aerosols and Dust -102
Accurate measurements of exposures to aerosols and dusts by plant personnel can be tricky. Here is some help for determining exposures and addressing uncertainties

Efficiency in Pneumatic-Conveying Air Filters -109
Paying closer attention to the air-filtration systems of pneumatic conveying operations can avoid losses in efficiency in compressed-air usage during filter cleaning

Minimizing Risk for Combustible Dust Explosions -113
By focusing on ignition sources, such as static discharges, and housekeeping, facilities handling solids can minimize their risk for combustible dust explosions

Technologies for Controlling H2S -120
There are many industrial technologies for removing H2S from process gas, and each brings with it different benefits with regard to costs, efficiency and equipment layout

Global Air-Pollution Regulations: Variation is the Norm -125
Operators with facilities in many countries need to focus on the requirements of each

Prevent combustible dust explosions with n2 Inerting- 129
Targeted use of blanketing with inert gas offers an effective strategy for preventing combustible dust explosions in CPI facilities

Design and Calculation Methods for Uniflow Cyclones- 135
Uniflow cyclones can be effective solid-gas separation equipment when space is limited. Presented here are design and calculation methods for uniflow cyclones aimed at widening the industrial usefulness of these devices

Piping-System Leak Detection and Monitoring for the CPI- 145
Eliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design

NFPA 652: Standardizing Combustible Dust Standards- 152
The latest NFPA standard applies to many industry sectors, and aims to address the fragmented nature of the industry-specific standards currently in place

Dust Explosions: Prevention & Protection -157
Understand what causes these disasters and then put these practical measures in place

Safety in Sulfuric Acid Storage Tanks -162
Commonly used in the CPI, sulfuric acid requires many special precautions to ensure its safe handling and storage

Dust Management in Bulk-Material-Handling Operations- 168
Dust management can be divided into three main categories: prevention, containment and suppression. Understanding the key considerations for each can help bulk solids handlers arrive at an optimal dust control solution

Powder and Bulk Solids Handling: Particle Size and Distribution Analysis- 178
The size and size distribution of particles are important determining factors in the design and operation of many process operations involving dry particles and powders. Follow this guidance to understand the impact of these key characteristics

Combustible Dust Fires and Explosions: Recent Data and Lessons Learned- 183
A review of recent data from the Combustible Dust Incident Database provides insights into dust-related process safety

Forces Acting on a Gasket -186

Industrial Adsorbents -187

Emissions Regulations and Control -188
Harnessing new technologies for best practices in pollution control could lead to a more ideal framework of policies and programs

Valves: Emissions Standards and Current Practices -193
New industry standards aimed at reducing fugitive emissions have necessitated updates to valve-testing procedures and a renewed focus on high-performance sealing and packing technologies

The Benefits of Seal-less Pumps for Full Product Containment -197
In cases where full containment of dangerous and hazardous chemicals is necessary, seal-less pumps can provide many safety and operational benefits

Magnetically Coupled Pumps: Structure, Function and Best Practice- 201
Understanding pump internals, especially the various sealing and coupling arrangements, is a critical step in selecting the optimal pump

Spill Containment: An Often-Overlooked Hazard in Research- 208
With proper planning, spills can be managed properly and the risk of secondary events — which may be more dangerous and costly — can be reduced

Odor Issues and Solutions for Wastewater Treatment- 216
Increasingly, wastewater treatment plants must address odors due to volatile contaminants. This guide provides an overview of odor causes and possible remedial actions

Air-Pollution Control Volume 2: Focus on High-Temperature Operations

This collection of how-to articles provides useful engineering guidance on an array of topics related to monitoring and managing vapor and particulate emissions that can arise during chemical process operations.
Several articles provide recommendations for understanding environmental regulations, while others share tips for reducing or eliminating fugitive emissions from tanks, burners and combustion units, and other process equipment. There is also focus on optimizing flare systems.
The articles were originally published in Chemical Engineering magazine, from 2012 through 2017. This Guidebook is part of a 2-Volume Set; Volume 1 is sold separately.
Delivered in a PDF format, 125 pages.
Topics Include:
Gas Hazard Definitions and Data
Gas Detection
Activated Carbon
Air Pollution Control: Assessing the Options
Considering Fugitive Emissions During the Conceptual Design Stage
Emissions Regulations and Control
Designing Atmosphere Storage Tanks
Safety in Sulfuric Acid Storage Tanks
Clearing the Air About Respiratory Protection
Reliable Operation and Sealing of Agitators
Eye on Flare Systems
Flare-Gas Recovery Methods for Olefin Plants
Optimizing Flare Operation Through Proper Design
Flare Consolidation Considerations
Advanced Control Methods for Combustion
Burner Inspection and Maintenance
Post-Combustion Carbon Capture Technology
Activated Carbon: Fundamentals and New Applications
Measuring Explosions to Aersols and Dust
Engineering for Plant Safety
Common Mistakes When Conducting a HAZOP and How to Avoid Them
Controlling S02 Without Corroding the Bottom Line

Improving Plant Operability Focus on Reliability- Volume One

Volume one of this two-part guidebook contains practical, how-to engineering articles, and useful engineering “Facts at Your Fingertips” tip sheets. All were originally published in Chemical Engineering.
The collection of articles in this volume focuses on a range of reliability issues affecting a large array of equipment types and unit operations. Several articles discuss improving the reliability of pumps, valves and heat-transfer systems. Others focus on making the most of instrumentation systems that can help to improve plant reliability, while providing guidance on proper equipment selection and monitoring techniques to reduce corrosion risk.
Several articles cover optimizing overall process operations through improvement engineering and proper management of turndown and rangeability, and on improving maintenance techniques to reduce unplanned downtime.
These articles were originally published between 2008 through 2015. This guidebook is available in PDF format only. The other volume of this two-part set, entitled, “Improving Plant Operability — Volume Two: Focus on Safety,” is sold separately.
Delivered in a PDF, 233 pages.
Table of Contents
Facts at Your Fingertips: Maximizing Fan Efficiency
Facts at Your Fingertips: Pressure Measurement Considerations
Project Optimization Through EngineeringFollow these practical recommendations to reduce capital outlay and operating costs, deliver shorter schedules and improve design quality
Advances in Process Temperature Measurement: Trends and TechnologiesProcess temperature measurement is a constantly evolving field, and new technologies have allowed for more reliable measurements to be realized in many applications
Facts at Your Fingertips: Hot-Oil Heat-Tracing Systems
Extremely Low-Temperature SystemsUnderstanding the nuances of low-temperature engineering is key to safe and efficient operations
New Measurement Practices for Cold ClimatesSelecting the right pressure, temperature, flow and level meters and connection systems can help to eliminate the need for heated enclosures and sensing lines
CPI Machinery: Commissioning, Startup and PipingPractical notes on installation, piping, support, layout, nozzle-loads, stress analysis, pre-commissioning, commissioning, startup and operation of rotating machinery
Optimization of a Steam NetworkProper configuration of steam-turbine drivers affects power generation in petroleum refineries
Design Underground Piping for SafetyBuried systems bear a number of unique risks and require special considerations, including those related to soil characteristics and seismic loads
Evaluate Heat-Exchanger Tube-Rupture Scenarios Using Dynamic SimulationApplying dynamic simulation models to tube-rupture scenarios can help ensure more accurate sizing and hazard assessments
Bulk Solids: Optimizing Screw ConveyorsDespite their apparent simplicity, the complexity of these conveying systems demands proper design and an understanding of the underlying principles
Computerized Maintenance Management Systems For Effective Plant PerformanceCorralling gigabytes of predictive maintenance data isn’t easy, but it’s essential for streamlining your process
Get the Most out of Vibration AnalysisBy listening to the messages your components are sending, you will be better able to assess the status of your machinery and take action to address problems
Facts at Your Fingertips: The Impact of Off-BEP Pump Operation
Gas Turbines: Design and Operating ConsiderationsFollow these engineering recommendations to improve gas turbine operation and performance while reducing operating costs
Valve-Selection Best PracticesPrecise combinations of valves and other equipment lead to process success. A biopolymer fermentation process provides an example of proper valve selection
Maximizing Performance In Size Reduction Expect more in selection and scaleup, prediction of energy consumption and reliability
Dynamic Modeling for Steam System ControlDynamic modeling fills in the gaps of steady-state modeling and provides a more complete, reliable and efficient analysis
Industrial Control Systems Security: The Owner-Operator’s Challenge Addressing the cybersecurity of industrial control systems requires a collaborative response, beginning with a realistic assessment
Combining the use of Rupture Discs with Relief Valves Using the two devices together offers significant benefits in chemical processes. Here is how to take advantage of them
Filtration and Separation During Chemical Process Operations: Avoid Common Errors The seven commonly made mistakes discussed here often lead to poor filtration and separation performance and many associated problems
Measuring Exposures to Aerosols and DustAccurate measurements of exposures to aerosols and dusts by plant personnel can be tricky. Here is some help for determining exposures and addressing uncertainties
Mitigate Corrosion in Condensate-Return Systems Understanding the chemistry behind corrosion in condensate-return systems can aid in selecting and properly employing the best mitigation technique
Facts at Your Fingertips: Steel Corrosion
Determining Friction Factors in Turbulent Pipe FlowSeveral approaches are reviewed for calculating fluid-flow friction factors in fluid mechanics problems using the Colebrook equation
Five Steps to Replacing Aged Heat-Transfer FluidFollow these guidelines to help ensure efficient operation of heat transfer systems, and proper exchange and disposal of aged fluids
Optimal Cooling Systems for Coastal Plants When all economic and environmental factors are considered, a cooling tower may be the best option
Piping-System Leak Detection and Monitoring for the CPIEliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design
Best Practices for the Control of Fuel Gas Adopt these practices to ensure new project success, and to achieve safe control and reliable, efficient operation going forward
Managing Large Chemical Plant Startups Prudent planning and scheduling during a project’s front end can lead to more expedient commissioning and startup activities
Critical Connections Demand CertaintyUnderstanding bolts’ behavior during routine tightening procedures helps to ensure leak-free, reliable operations
Industrial Insulation Systems: Material Selection FactorsTo provide the desired functions while being exposed to harsh environments, insulation material should be carefully selected and specified to meet the design goals
Pressure Transmitter Basics: Selection GuidelinesClimbing the decision tree to pick the right pressure sensor
Pneumatic Conveying: Optimal System Design, Operation and ControlNumerous strategies and options for both dilute- and dense-phase conveying systems are presented here
Pipe Insulation: Finding the Optimal ThicknessAvoid tedious numerical calculation by using this quick, shortcut method
Optimizing Flare Operation Through Proper DesignFlare problems are often caused by the seal systems that are designed to control air ingress. Follow these troubleshooting guidelines to improve design and ensure safe, reliable flare operation
Facts at Your Fingertips: Industrial Adsorbents
Improving the Operability of Process PlantsTurndown and rangeability have a big impact on the flexibility and efficiency of chemical process operations
Calculate NPSH with ConfidenceDetermining net positive suction head (NPSH) can be confusing, but with these guidelines, engineers can avoid the pitfalls of incorrect calculations
Applying CPI Temperature SensorsDon’t fall back on outdated rules of thumb that may no longer be valid, or ‘plug and play’ solutions that may not be applicable
Specifying Elastomer Seals for Plastic PipingCareful attention to elastomer properties and variation by manufacturer can help optimize specification
Mechanical Seals Update: Pharmaceutical and Food ApplicationsFor applications that require cleanliness, be sure your centrifugal pumps have the proper seals
Troubleshooting Tube-Deterioration Mechanisms in Direct-Fired Heaters

Liquid-Liquid and Gas-Liquid Separation

CHAPTERS: Chapter 1. Distillation; Chapter 2. Absorption and adsorption; Chapter 3. Crystallization; Chapter 4. Evaporation and condensation); Chapter 5. Vacuum processing; Chapter 6. Data and calculations; Chapter 7. Related topics

CHAPTER 1. DISTILLATION

Designing azeotropic distillation columns
Stanislaw Wasylkiewicz and Leo Kobylka, AEA Technology Engineering Software, Hyprotech Ltd., Marco Satyro, SEA, Inc.

Extractive distillation: Separating close-boiling-point components
Fu-Ming Lee, GTC Technology Corp.

Recovering and recycling low-boiling alcohols and ketones
George Schlowsky and Brian Loftus, Koch Modular Process Systems LLC

Partitioned distillation columns Why, when and how
Hans Beckeer, Sven Godorr and Helmut Kreis, Linde AG; James Vaughn, Sasol Technology

Separation using coupled reactive distillation columns
Erik Stein, Achim Kienle, Kai Sundmacher, Max-Planck-Institute for Dynamics of Complex Technical Systems

Advanced distillation saves energy and capital
Frigyes Lestak and Cyril Collins, M.W. Kellogg Ltd.

Catalytic distillation extends its reach
Kerry Rock, Gary Gildert and Tim McGuirk, CDTech

Distillation tower flooding More complex than you think
Simon Xu and Lowell Pless, Tru-Tec Services, Inc.

Giving insight to difficult distillations by replotting the McCabe-Thiele Diagram
James Ryan, Ryan Consulting

Distillation reboiler startup can pose challenges
Etienne Rubbers, Kirsten Green and Terry Fowler, Sasol Technology Pty Ltd., and Hendry Kister and Walter Stupin, Fluor

Solving a tower’s salt-plugging problem
Henry Kister, Fluor Daniel , Shihan Chen, Honeywell International

CHAPTER 2. ABSORPTION AND ADSORPTION

Simplify calculations for absorption with chemical reactions
Jerry Meldon, Tufts University

Selecting the solvent for SO2-removal absorption
Soumitro Nagpl and P.K. Sen, Engineers India Ltd.

Scrubbers with a level head
George C. Pedersen, Kimre, Inc ., and P.K. Bhattachararjee, U.S. Agri-Chemical Corp.

Wet scrubbers: Choose the best chemical reagent
Ing. Noe Ugo Rinaldi, Tecnochim s.r.l

Wet scrubbers: Match the spray nozzle to the operation
Lothar Bendig, Lechler GmbH & Co. KG

Taking stock of activated carbon’s many talents
Stephanie Carr and Robert Vaughn, Calgon Carbon Corp.

Removing H2S from gas streams
Gary Nagl, U.S. Filter Gas Technology Products

Prevent thermal runaways in carbon beds
Thomas Hofelich, Marabeth LaBarge, and Denise Drott, Dow Chemical Co.

CHAPTER 3. CRYSTALLIZATION

Simplify multicomponent crystallization
Joseph Schroer, University of Massachusetts (Amherst) and Ka M. Ng, Hong Kong University of Science and Technology

Making big crystals
Richard C. Bennett, Crystallization Technology, Inc.

Crystallization’s forgotten facet
Wayne J. Genck, Genck International

Coping with crystallization problems
B.C. Sutradhar, Invista, Inc.

Better growth in batch crystallizers
Wayne J. Genck, Genck International

CHAPTER 4. EVAPORATION AND CONDENSATION

Optimizing process vacuum condensers
James R. Lines and David W. Tice, Graham Manufacturing Co.

Gravity effects in horizontal condensers
Alejandro Anaya Durand, Cynthia A. Aguilar Guerrero, Edgar Amaro Ronces, National Autonomous University of Mexico

A shortcut for designing evaporators
Alejandro Anaya Durand, Instituo Mexicano del Petroleo

Scaleup of agitated thin-film evaporators
William B. Glover, LCI Corp.

CHAPTER 5. VACUUM PROCESSING

Improving vacuum systems
Terrence Fay and Jarema N. Kraus, Lockwood Greene Engineers, Inc., Mitchell J. Levy, Consultant

Difficult to process? Vacuum it!
Andrew J. Eckles, Atlanta Technology Group

Proper piping for vacuum systems
Loren Wetzel, Graham Manufacturing Co.

Choose the right vacuum pump
Joe Aliasso, Graham Manufacturing Co.

CHAPTER 6. DATA AND CALCULATIONS

Simplify flash calculations
Philip Eubank, M. Sam Mannan and Kenneth Hall, Texas A&M University

Use a spreadsheet to fit vapor-liquid equilibrium data
Victoria Paulsen, Koch Modular Process Systems LLC

Solubility & Henry’s Law constants for sulfur compounds in water
Carl Yaws, Praveen Bajaj, and Harman Singh, Lamar University, Ralph Pike, Louisiana State University

Solubility and Henry’s Law constants for amines in water
Carl Yaws, Jack Hopper and Sunil Mishra, Lamar University

CHAPTER 7. RELATED TOPICS

Apply liquid-liquid extraction to today’s problems
Roger W. Cusack and Donald J. Glatz, Glitsch Process Systems, Inc.

Difficult liquid-liquid separations
Thomal H. Wines, Pall Corp. , Robert L. Brown

Designing a separation process
Rocger W. Cusack, Koch Process Technologies, Inc.

Separation simulation via spreadsheet
Andrew Wilson, Solvay Specialty Chemical Co.

Processing with supercritical solvents
James McClain, Micell Technologies

Hybrid separation schemes for CO2 removal: Conditioning natural gas
William Echt, UOP LLC

Hybrid separation schemes for producing organic acids
Mathieu Bailly and Daniel Bar, Eurodia Industrie SA

The many faces of ion-exchange resins
James T. McNulty, Rohm and Haas Co.

Demystifying mist eliminator selection
Steven Ziebold, Monsanto Enviro-Chem Systems, Inc.

Put a centrifugal spin on solvent extraction
D. Greg Cybulski and Robert Driscoll, Rousselet-Robatel Centrifugation

Facts at Your Fingertips Guidebook 2018

High-Shear Mixing
Flow Measurement in Large Lines, Ducts and Stacks
Industrial Combustion Products
Corrosion Complications
Activated Sludge Process
Seal Material Properties
UN Codes for Packaging Dangerous Goods
Maintaining Heat-Transfer-Fluid Quality
Kilogram Standard
Filtration Process Design and Optimization
Resistance Temperature Detectors
Distillation: Comparing Experiments and Simulations

Facts at Your Fingertips 2017

Chemical Engineering’s Facts At Your Fingertips package includes a series of twelve condensed, one-page reference cards that provide useful rules of thumb, common equations and other practical tips for designing, operating and maintaining chemical process equipment.This guidebook is available in a downloadable PDF.The topics covered in 2017 include the following:
Solids-Blending ProcessesBatch versus continuous, Blending mechanisms, Random versus ordered blend, Segregation and sampling
Steam ConceptsPressure-temperature relation, Wet steam region, Industrial practice, Steam grades
FermentationFermentation advantages, Fermentation challenges
Gas DetectionGas sensor classes
Pressure-Based Level MeasurementDifferential pressure
Alarm ManagementAlarm frequency, Average alarm rate, Causes of high alarm rates
ZeolitesZeolite structure, Major industrial uses, Catalysis chemistry
BlendingBatch blending, Continuous blending, Questions to consider
Heat-Transfer Fluid SelectionProcess requirements, Cost of ownership, Product and data support
Air Separation ProcessesAir separation approaches, Non-cryogenic air separation, Cryogenic separation
Filter AidsFilter aid function, Filter aid materials, Filter aid selection
Agglomeration and GranulationWet agglomeration, Compaction processes

Improving Plant Operability Focus on Safety- Volume Two

Volume two of this two-part guidebook contains practical, how-to engineering articles, and engineering tip sheets from the “Facts at Your Fingertips.” All were originally published in Chemical Engineering. Since safety is key in all chemical process plants, this volume provides many useful engineering recommendations for improving safety in all aspects of plant operation and maintenance.
This guidebook gives broad, plant-wide recommendations for improving plant safety and reducing risk to personnel, plant operation and the environment. There is focus on specific engineering topics including proper monitoring and control of high temperatures, managing static electricity, reducing fire and explosion risk, reducing risks in laboratories, proper waste-handling procedures, selection guidance for personnel-protective gear, reducing the risk of dust explosions, managing MSDSs, proper chemicals-handling techniques and more. Focus is on specific engineering components, such as rotating machinery, vacuum systems, burners and flares.
201 pages, delivered in a PDF format
Table of Contents
Tolerable RiskWhile determined risk is generally well understood, tolerable risk can be the missing link to complete risk assessments
Chemical Lifecycle ManagementSustainability demands a higher level of oversight that seeks new ways to effectively and cost efficiently procure, handle and dispose of, or recycle materials
Hearing Protection For CPI WorkersAs statistics on rising rates of noise-induced hearing loss in the workplace show, a hearing-conservation program alone is not enough. Workers must understand the risks, have access to hearing protection and, most importantly, use it
Designing for a Safe ProcessIncorporating safety considerations throughout process design lowers the risk of a hazardous event
Heat Transfer Fluid Leaks: Break the Fire TriangleExtreme processing temperatures present the greatest risk. Know where leaks are most likely to occur andhow to prevent them
Avoiding Static Sparks in Hazardous AtmospheresRelatively simple steps can be taken to mitigate risks associated with static electricity in process plants
A Checklist for Safer Chemical Batch ReactionsA good understanding of the reaction chemistry is needed for a safe process design
A Safety-Centered Approach to Industrial LightingThe proper design and operation of lighting is essential to ensure plant safety and support good maintenance practices
Designing Safer Process PlantsSeveral often-overlooked strategies to increase inherent safety are discussed here
A Safety Checklist for LaboratoriesThese nine best practices for managing change in laboratories can help ensure a safe workplace
Engineering for Plant SafetyEarly process-hazards analyses can lead to potential cost savings in project and plant operations
Chemical Lifecycle ManagementSustainability demands a higher level of oversight that seeks new ways to effectively and cost efficiently procure, handle and dispose of, or recycle materials
Clearing the Air About Respiratory ProtectionLearn the basics about selection and regulatory compliance for these potentially life-saving devices
Fire-Water Pumps for CPI FacilitiesFollow this guidance to improve the selection, design and operation of pumps handling water for firefighting and related systems
Eye-and-Face Personal Protective EquipmentProtecting the eyes and face in the workplace is imperative to preventing the estimated 10–20% of workrelated eye injuries that result in temporary or permanent vision loss
Managing Compliant MSDSs and LabelsCompliant MSDS programs depend on inventory management, regulatory knowledge and consistent authoring
Effective Plant Safety ManagementThree critical junctures and seven critical steps for plant safety are outlined
Remote Thermal SensingBy making it easy to detect heat anomalies, thermal cameras and infrared thermometers support preventive and predictive maintenance
Finding the Right Gloves to Fit the ApplicationThere is a wide range of gloves available for hand protection on the job. Matching gloves to their chemicalresistance properties is one criterion for selection
Dust Control in the Chemical Processing IndustriesThe prevention of dust hazards in the CPI is integral to process-safety management — wide-reaching mitigation schemes must be implemented
The Integral Role of Waste Management in Capital ProjectsTo avoid unnecessary efforts and mitigate risks, all phases throughout the design and implementation of large capital projects should incorporate comprehensive planning for waste management
Why Bad Things Happen to Good Steam EquipmentAccounting for an entire steam-trap population is crucial to avoiding safety incidents and suboptimal production — high-priority consideration must be given to steam-system management
Rotating Machinery: What You Should Know About Operational ProblemsFollow this guidance to improve the operation, safety and reliability of rotating machinery in chemical process plants
Chemical Protective ClothingISO 16602 offers a much-needed, common global language for expressing protective clothing performance
Technology Profile: Propylene Production via Metathesis
Preventing Fires and Explosions in Pilot PlantsThe issues and complications are different from — and in many ways more challenging than — those for full-scale plants
Fire & Gas in Safety SystemsIntegrating fire-and-gas detectors and mitigation systems into overall process safety control can help ensure fast responses to emergencies
Anti-surge Valves for Dynamic CompressorsFollow this guidance to improve the selection and sizing of anti-surge valves for axial and centrifugal compressors
Preventing Dust ExplosionsRisk management programs are critical for safe handling and processing of combustible dust as well as for OSHA regulatory compliance