Airborne respiratory hazards are a very real threat in the chemical process industries (CPI). Existing in a variety of forms including gases, vapors, dusts, mists, fumes, smoke, sprays and fog, such hazards can cause illnesses including cancer and lung impairment,…
Companies in the chemical process industries (CPI) spend billions of dollars every year on capital projects. Most are successful, yielding the desired results. Some projects are only partially successful (and therefore partial failures), in that they are ultimately completed and…
Equipment for generating synthesis gas (syngas; mostly CO and H2) is typically the most expensive part of an overall gasification complex. Understandably, the owners of gasification assets seek the highest value for the syngas produced by these assets. The methodology…
Preventing dust explosions is not rocket science, and still these disasters occur. This article is written to help prevent these accidents. It describes how and why these explosions happen and what can be done to avoid them. Why they occur…
One of the most significant limitations on the operation of dynamic compressors (axial and centrifugal compressors) is the low-flow limit known as “surge”. A sudden valve closing, such as for emergency shutdowns or for a suction/discharge valve, presents significant challenges…
The prices of low-voltage variable frequency drives (VFDs) have declined substantially since they were introduced, while the cost of power has increased. Normal project economics will now justify these VFDs — which go up to 375 kW (500 hp) or…
For most solids-processing operations in the chemical process industries (CPI), particle-size reduction and screening (classification) to achieve the desired particle-size are required, since processes rarely produce the desired size directly. When designing processes, selecting equipment and looking for ways to…
Many CPI applications require the injection of chemicals, such as corrosion inhibitors, precipitation inhibitors, oxygen scavengers and countless others, into the process during operation. Follow these tips to design and operate a system that ensures accurate delivery of performance chemicals,…
This article covers permitting and directly related design issues associated with thermal processes used for drying and calcining, using the production of ceramic proppants as an illustrative example. While the magnitude of permitting issues varies significantly with air-quality attainment area…
Inorganic acids play a major role in the chemical process industries (CPI). They are used as raw materials, catalysts or finishing and pH control agents in the manufacture of a wide range of chemical products, from fertilizers to detergents, and…