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Industrial uses of water are many: in cooling towers, condensers and boilers, as process and wash fluids and more. Treatment of water is often needed, to prevent corrosion for example, and for reuse or disposal. With water scarcity as a serious global challenge, efforts to conserve, treat and reuse water, as well as to reclaim water via desalination are leading to new technological advancements.
This collection of articles from Chemical Engineering and POWER magazines presents a timely and informative overview of global efforts on industrialwater-related topics. It includes articles on cooling water, boilers, water conservation, wastewater treatment, some of the latest technological advancements and more.
Delivered in a PDF format. 199 pages.
Articles include:
Section One
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 
Biological Wastewater Treatment: Maintaining the Needed Microorganism PopulationActivated sludge processes are inherently complex. Proper system design, operation and maintenance are essential to adequately break down target organic materials
Cooling Towers: Managing Tighter Water-Discharge RegulationsTightening regulations for cooling tower water-discharge quality are requiring plant engineers to evaluate enhanced treatment options, sometimes including zero-liquid-discharge systems
Water Takes the Stage at AchemaThe emphasis on water management at Achema 2015 indicates the critical nature of water to all industry sectors as the CPI expand and evolve
Cooling Towers: Estimate Evaporation Loss and Makeup Water RequirementsApplying mass and energy balance calculations yields critical operating insight
Superheater Problems in Steam GeneratorsKnowing the features of a good boiler will prevent problems associated with a poor design
Pressurized Piping: Sampling Steam and WaterWithout proper systems, analysis of steam and water chemistry can provide erroneous results — with costly implications
A Primer on Reverse Osmosis TechnologyDesalination by reverse osmosis is a key technology for a water-constrained world. Discussed here is its use in industrial water treatment and drinking-water production
Mitigate Corrosion in Condensate-Return SystemsUnderstanding the chemistry behind corrosion in condensate-return systems can aid in selecting and properly employing the best mitigation technique
Beware of Flow-Accelerated CorrosionOperators of steam-generating systems should understand flow-accelerated corrosion and the potential problems it can cause
Water-Saving Strategies for the CPIWater savings at CPI facilities depend on effective water management, smart application of technology and corporate supportThe Financial Benefits of Water TreatmentDue to the rising costs of water use and disposal, improved treatment technologies make economic sense
Troubleshooting and Solving a Sour-Water Stripper ProblemA systematic approach identifies problems that prevented a stripper column from achieving trouble-free operation
Understanding Boiler CirculationProper arrangement of drum baffling, sizing and location of dowcomers and risers will ensure a good natural-circulation system
Biological Wastewater Treatment: Selecting the ProcessBasic steps for developing an industrial-water-treatment process are given, using an example of a difficult-to-biodegrade wastewater stream
Treating Wastewater for Industrial ReuseSecondary treated wastewater from municipal plants can be a water resource for industry. Important water characteristics and treatment options are discussed
Advantages Gained in Automating Industrial Wastewater Treatment PlantsProcess monitoring and automation can improve efficiencies in wastewater treatment systems. A number of parameters well worth monitoring, as well as tips for implementation are described
How To Properly Size A Steam TrapDon’t confuse the size of a steam-trap’s end connection with the internal discharge orifice for condensate
Modern Water-Treatment ChallengesLNG and other facilities that are expanding due to the shale-gas boom face specific challenges when it comes to ensuring the purity of the inlet and outlet water
Challenges of Drying Sticky Wastewater SludgeIn wastewater-sludge drying and dewatering operations, many issues arise from the sticky properties of the sludge. Here are some insights to address them
Using Sensor Technologies to Optimize Maintenance of Power Plant Water SystemsNondestructive technologies make the inspection of a plant’s least accessible components relatively easy and deliver results that minimize unexpected failure—and expense.
Desalination Expands, but Energy Challenges RemainFearing widespread water scarcity, companies and governments around the world are scoping out desalination technologies to convert seawater to potable water. That’s a rocky path that involves lots of energy and high costs—and potentially high rewards.
Monitoring and Treatment of Closed-Loop Cooling Water SystemsIn part because they are closed-loop systems, it can be easy to ignore power plant cooling water systems that support the reliable functioning of everything from stator bars in the generator to critical pump bearings for feed pumps and heat exchangers on air compressors. Proper monitoring and maintenance of these water systems can help you avoid more-costly repairs to the mechanical systems they cool.
Zero-Discharge Pozzolanic Brine Solidification: Another Option for Treating FGD WastewaterWith its expected 30% to 50% lower capital expense and 20% to 40% lower operating cost than traditional zero-discharge systems, a new approach to compliance with the EPA’s effluent limitation guidelines could be attractive.
A Comparison of ELG Compliance Options for Flue Scrubber WastewaterMeeting the requirements of the Effluent Limitations Guidelines (ELG) means careful consideration of the various options. Both biological treatment and zero liquid discharge (ZLD) approaches have their place, but ZLD may offer more flexibility for the future.
Lowering Cost and Waste in Flue Gas Desulfurization Wastewater TreatmentMany informative articles have been published about options for treating flue gas desulfurization wastewater, but new technologies are rapidly changing the treatment possibilities. This article reviews key economic considerations and introduces an innovative treatment solution that lowers costs and the amount of waste generated.
Reclaimed Water Reduces Stress on Freshwater SuppliesPower generation need not be another source of strain on diminishing freshwater resources. Wellestablished water reclamation technologies are enabling producers to conserve resources—and money.
Using Reclaimed Water in Power Plant Cooling ApplicationsUsing reclaimed water as a makeup supply for cooling tower systems has become a popular option for reducing impacts on local water resources, but it comes with its own challenges because of its unique chemistry. Use of a novel terpolymer can greatly reduce the operational costs involved.
Huaneng Power’s Changxing Station ZLD Project, ChinaTo satisfy China’s more stringent water use and air pollution rules, developers of the new 1.3-GW ultrasupercritical coal-fired Changxing Power Plant used a novel forward osmosis–based brine concentration and water reuse process to treat flue gas desulfurization wastewater for zero liquid discharge (ZLD). It is the world’s first commercial application of this technology.
Prevent Purified Water from Putting a Damper on Your Next CommissioningWhen commissioning a new power plant, requirements for purified water can be large—often more than an unfinished plant can supply. When it’s time to bring in outside help, proper planning can help avoid problems and keep budgets under control.
Next-Generation FGD Wastewater Bioreactor Technology Introduced for ELG ComplianceCompliance with one of the latest federal environmental regulations, the Effluent Limitations Guidelines (ELG), can be both costly and complicated. A newly available option offers features and capabilities that may make it a more attractive alternative than conventional approaches.
Section Two- Technology Briefs
A new adsorbent to recover uranium and other heavy metals from wastewaterBacteria and algae team-up to tackle arsenic-contaminated waterThese robust organosilane-based membranes promise benefitsAn inexpensive adsorbant for removing silver from wastewaterA self-cleaning electrolytic cell that converts waste streams into disinfectantsEngineered wetlands technology now available for wastewater treatmentCoral enhances the removal of mercury from wastewaterRemoving harmful metals from wastewater with crab shellsImproving the efficiency of solar desalinationOrganic corrosion inhibitors perform well against oxidizing biocidesCarbon fibers enhance swine wastewater treatmentA new adsorbent for wastewater treatmentImitating nature leads to a separator for oil dropletsThis new water-treatment polymer improves scale control in boilersA pilot project to capture rainwater for wine productionRemove pollutants from wastewater with this nano-tailored coatingCovered lagoons treat wastewater and make biogas, tooA desalination membrane that is resistant to chlorineA patent granted for this self-diagnostic technology used in boilersReduce energy costs by combining wastewater treatment and desalinationUsing algae to clean wastewaterDiamond-based electrodes allow handling of difficult-to-treat wastewatersThis scale inhibitor uses steric dispersion principlesA next-generation membrane bioreactorMicroporous vanadosilicate efficiently removes cesium from wastewaterMunicipal water sludge-optimization technology poised for growthCeramic membrane filtration to be demonstrated for removing oil from produced waterPhosphorus-free cooling water treatmentA process to treat tight emulsions and intractable oily wastesAn energy-saving bioreactor for wastewater treatmentNanostructured membrane for water purificationControl biofouling with I2-vapor disinfectionA new carrier for MBBR technology‘Switchable solvent’ technology is a promising development for advancing forward osmosisThis chemical-free disinfection media requires no powerTurning wastewater treatment into resource recoveryPlasma oxidation disinfects water without the addition of chemicalsThis desalination process uses much less energy than ROBioelectrochemical system treats wastewater and generates biogasContinuously cleaned filters for challenging water streamsA new catalyst removes cyanide from wastewaterConverting sewage into fuels

Reactors are an essential part of many chemical process operations, and sound design is essential for maximizing reaction rates and optimizing throughput rates. The articles in this guidebook provide useful engineering information related to the design, operation and maintenance of agitated reactors, continuous stirred-tank reactors, millichannel reactors and other reactor designs.
There is focus on increasing reaction rates and throughput through the use of improved mixing strategies, the use of heuristic rules, and enhanced understanding of the physical properties of the fluids involved.
Several of the provided tutorial-style articles provide guidance on using pinch technology and process modeling to improve reactor operation and reduce utility consumption. Additional engineering recommendations are provided for analyzing and improving heat transfer and mass transfer in reactor systems.
98 pages, delivered in a PDF format.
Table of Contents
Mixing Systems: Design and Scale UpMany options are available to meet the mixing challenges confronted by the CPI. Both theoretical and empirical methods can help the engineer to fit the right system to the task
How to Handle Hydrogen In Process PlantsProcess-unit layout, piping, instrumentation/control and materials of construction are but a few of the technical issues requiring special attention during the design or retrofitting of process plants that use hydrogen as a raw material
Know Your Hydrogen- Supply OptionsThe best delivery method for your process unit depends on your plant location, and on the amount and purity of hydrogen you need
Mechanical Design Aspects for High-Performance Agitated ReactorsAn understanding of the mechanical design helps in specifying, maintaining and revamping agitated reactor systems
Focus on Physical Properties To Improve ProcessesExploiting the physical properties of chemicals can offer pathways to more simplified and elegant processes
Facts at Your Fingertips: Gas-Liquid Mixing: Physical Considerations
Millichannel Reactors: A Practical Middle Ground for ProductionReactors with millimeter-scale dimensions provide mixing, heat transfer and other advantages over devices with larger dimensions, and increased robustness compared to microdevices. Here are tips to consider for using them
Adiabatic-Temperature Rise: An Awkward Calculation Made SimpleHow to estimate a final temperature after a reaction
CSTRs: Bound for Maximum ConversionHere, a design approach for continuous stirred-tank reactors is outlined for both reversible and irreversible second-order reactions
Maintenance and Repair of Glass-Lined EquipmentA customized inspection and maintenance program will minimize operational and performance problems
Non-ideal Gas Calculations Using Analytical ResidualsA refresher on simplified calculations of thermodynamic changes of real gases
Making Emulsions Vacuum processors give cosmetics and pharmaceuticals the smooth treatment Process Modeling Moves Center-StageA model solution for the CPI: reducing risk while increasing profit
Heat Transfer for Huge- Scale FermentationThe impact of ten-fold scaleup is explored here
Heuristics Rules for Process EquipmentIf applied with thought and care, heuristics like these can make life much easier during project scoping, process design, equipment specification and similar tasks
Increase Productivity Through Better Gas-Liquid MixingThe trend towards larger reactors has increased the demand on agitator systems. Developments in gas-liquid mixing technology can help meet these demands
From Batch to Continuous ProcessingContinuous flow reactors can provide many benefits over batch processes. This article answers why and how
CSTR Design for Reversible ReactionsHere, a design approach for continuous stirred-tank reactors is outlined for three cases of second-order
Controlling Heat Transfer in Glass-Lined ReactorsUniform heating and precise temperature control can be achieved with thermal liquids

During chemical process operations, risk can take many forms. For instance, risk associated with management and engineering decisions can create a range of environmental, health and safety consequences, lead to sub-optimal process operations and depressed production yields, and incur additional maintenance and repair requirements.
Similarly, risk associated with project planning, modeling and execution can increase financial and business risk, by resulting in cost overruns and schedule delays, depressed profit margins and squandered market opportunities.
This two-volume Chemical Engineering Guidebook brings together a diverse array of engineering articles, to help facilities recognize all of the many forms of risk that can arise during chemical process operations, and take practical steps to manage the properly in order to optimize outcomes.
Delivered in a PDF format, 141 pages.
Articles Include:
Tolerable RiskWhile determined risk is generally well understood, tolerable risk can be the missing link to complete risk assessments
A Checklist for Safer Chemical Batch ReactionsA good understanding of the reaction chemistry is needed for a safe process design
Designing Safer Process PlantsSeveral often-overlooked strategies to increase inherent safety are discussed here
Better Chemistry By DesignSimulation software helps to create higher-performance, safer and more-economical CPI plants
Revamping Your Process PlantAn overview of some options to consider for increasing capacities
A Safety Checklist For LaboratoriesThese nine best practices for managing change in laboratories can help ensure a safe workplace
Designing for A Safe ProcessIncorporating safety considerations throughout process design lowers the risk of a hazardous event
Avoiding Project FailuresRecognize these key project-failure modes, so that corrective action can be taken
Plant Revamps and Turnarounds: Some Lessons LearnedAlthough time is always precious, taking shortcuts and skipping standard procedures can be costly
Improve Your Contingency Estimates for More Realistic Project BudgetsReliable risk-analysis and contingency-estimation practices help to better manage costs in CPI projects of all sizes
Managing Compliant MSDSs and LabelsCompliant MSDS programs depend on inventory management, regulatory knowledge and consistent authoring
Accelerating Process and Product DevelopmentThese simple strategies can be used to speed up and increase the success rates of R&D projects
Design Safer Solids Processing PlantsThis approach defines a systematic framework and points toward relevant sources in the public domain
Effective Plant Safety ManagementThree critical junctures and seven critical steps for plant safety are outlined
Safety-Instrumented Systems: Control Valves As Final ElementsThe scenarios presented here highlight the advantages and disadvantages of using a control valve in an SIS
Seven Tools for Project SuccessHaving the right tools is essential for success. These tools are of use to both novice and experienced project managers
Design Safety Instrumented Systems with Relevant DataLaboratory-based data can be too optimistic; some data from the field are too pessimistic. Here is how to deal withthat dilemma
Project Optimization Through EngineeringFollow these practical recommendations to reduce capital outlay and operating costs, deliver shorter schedules andimprove design quality
INDUSTRIAL CONTROL SYSTEMS SECURITY: The Owner-Operator’s ChallengeAddressing the cybersecurity of industrial control systems requires a collaborative response, beginning with a realisticassessment
Managing Material Safety Data Sheets in the WorkplaceWhile regulatory agencies outline requirements for communicating chemical hazards, the format of compliance isup to the employer. Software tools can be helpful aids in meeting these requirements
Condition-Based Maintenance Management Enhances ReliabilityUnderstand reliability, condition monitoring and maintenance management to keep rotating equipment in top form
Design of Experiments (DoE): Optimizing Products and Processes EfficientlyLearn how DoE can help save time and money in process design and optimization with this primer
The Owner Role in Capital ProjectsAvoid delays, cost overruns and more with significant owner involvement
Reactive Chemistry in the CPIImproper handling of reactive chemicals can result in catastrophic industrial disasters, anda clear understanding of these materials is essential for safe process-design practices
The Next Step Change in Process SafetyLeveraging the convergence of operational and information technologies can aid in minimizing risk
Measurement Best Practices for Safety Instrumented SystemsHow to comply with new standards to maximize plant safety and availability while minimizing life-cycle costs