Bob Ross isn’t the only one to have happy accidents. Accidental discoveries have significantly advanced the chemical industry and led to numerous groundbreaking innovations. These serendipitous findings have often paved the way for the development of new materials, processes and applications that have had a profound impact on various sectors.…

Time is critical when tracking down hazardous substances. Whether it’s trying to mitigate safety incidents before they happen, comply with applicable safety and environmental regulations, or gather all the pertinent information during an emergency involving a chemical spill, fire or natural disaster, having an efficient way to trace every ingredien…

The problem with particulate solids is they segregate every time we turn around. Why? Because they are a two-phase material and only about half is the solid we’re interested in. As a troubleshooter at corporate engineering, the most common call I got from plants was about blenders that didn’t blend. The problems arose because people believed some m…

In the news this week: The U.S. EPA finalizes methylene chloride ban; Plastics Treaty negotiations wrap up in Ottawa; and Dow and BASF report lower Q1 sales.By chemicalprocessing

In this episode, we explore the importance of storytelling in the chemical industry. From knowledge capture and transfer to making technical information understandable and engaging, storytelling aids in retaining tacit knowledge and contextual understanding and enhances employee engagement.By chemicalprocessing

In the chemical industry, digitalization and emissions monitoring are pressing operational challenges. While exploring the technological innovations behind these trends, attention often shifts to advanced software and precision sensing technologies. But the critical components that ensure the smooth operation of a process plant can be overlooked. C…

This week’s news roundup examines the collapse of the Francis Scott Key Bridge in Baltimore and how it could impact the chemical supply chain. We also learn that several U.S. oil companies are following in the footsteps of Dow by announcing their plans to utilize small nuclear reactors to meet their electricity requirements. And finally, in the Did…

In Case You Missed It brings the written word to life. In today’s episode, I will be reading an article from Andrew Sloley, Chemical Processing’s Plant InSites columnist. This column “Project Management: Workflows Matter” was published on our website on March 30, 2022. Written by: Andrew Sloley, Plant Insites columnist Read by: Traci Purdum, editor…

Executive Editor Jonathan Katz catches us up on what's new in the chemical industry.By chemicalprocessing

Research on team performance barriers finds that fatigue, workload, competing priorities, conflicting information, and lack of technical expertise are significant hurdles. Psychological safety is crucial for effective team environments, allowing individuals to speak up and admit uncertainty without fear of reprisal. Tools such as self-assessment gu…

The combination of high accuracy, versatility, direct mass measurement and minimal maintenance requirements make Coriolis meters suitable for various industrial applications. Unlike volumetric flow meters, Coriolis meters directly measure mass flow, making them less susceptible to variations in temperature, pressure and fluid density. To learn more…

This news roundup ponders an elevator to space and questions Chemours ethics.By chemicalprocessing

Exxon looks to balance fossil fuels with sustainability, Didion execs sentenced and yellow snow for battery recycling. This news roundup covers the chemical industry in February 2024.By chemicalprocessing

Upsets are going to happen, so why not plan for it? Learn how. In this episode of Distilled, we discuss managing upsets and distinguishing between shutdown-related and non-shutdown upsets. Dave points out a lot has changed over the years. Indeed, the preference is shutting down during upsets and advancements like safety instrumented systems aid in …

In today’s episode, Traci Purdum will be reading a column from contributing editor Dirk Willard. This column “Properly Vet Contractors” was published to chemicalprocessing.com October 19, 2021. Engineers once flew around the country to check out contractors’ facilities before signing deals. Nowadays, many bosses instead heavily rely on the Internet…

A sobering look at the economy, PFAS regulations continue, blue-ringed octopus key to sustainable energy, and black-mass recycling. All news found here: https://www.chemicalprocessing.com/industrynews Read by Executive Editor Jonathan Katz.By chemicalprocessing

The discussion revolves around operator training efficiency in the industry. Despite decades of training, companies often lack feedback on its effectiveness. New technologies like simulators and virtual reality offer objective ways to measure and improve training. Identifying and addressing deficiencies is crucial, similar to the aviation industry'…

Welcome to the In Case You Missed It edition of Chemical Processing’s Distilled Podcast -- This podcast and its transcript can be found at chemicalprocessing.com. I’m Traci Purdum, EIC of Chemical Processing. In Case You Missed It brings the written word to life. In today’s episode, I will be reading a column from contributing editor Dirk Willard. …

Predicaments can crop up at all stages of a chemical engineering career. Properly dealing with them without serious consequences often isn’t easy or sometimes even possible. You may face ethical as well as technical and political challenges. So, let’s look at a variety of these and how to deal with them. This edition of In Case You Missed It is bas…

In this episode we focus on alarm rationalization mistakes, emphasizing the importance of addressing underlying problems rather than just managing the steady-state alarm rate. The discussion highlights the need for a clear operator action for each alarm, uniqueness in alarms, and the impact of alarm floods on human factors. The conversation explore…

In this episode of Chemical Processing's Distilled Podcast, host Traci Purdum and guest Dave Strobhar, founder of Beville Engineering, discuss the importance of font size in operator training. They highlight concerns related to small font sizes on computer monitors used in control rooms, particularly with the increasing resolution of displays. Stro…

In the chemical industry, understanding the health of rotating equipment is crucial for safety and productivity. Regular inspections, compliance with regulations and proactive maintenance are vital for equipment reliability. Ares Panagoulias, the director of condition monitoring and test lab at Hydro Inc., emphasizes the importance of data in asses…

In this episode, Traci and Dave discuss the importance of reducing emergency procedures in chemical processing for better operator training and performance. They explore the benefits of streamlining procedures, emphasizing that about 90% of emergency steps are common across various situations. Dave advocates for simplified, condition-based procedur…

Helping operators learn from past incidents and use pattern recognition to make better decisions faster will improve safety and efficiency.By chemicalprocessing

SICK AG's David Inward on Chemical Industry Emissions MonitoringBy chemicalprocessing

In this podcast episode, Dave Strobhar discusses an innovative approach to calculating operator needs and the impact of automation on staffing in the process industry. He emphasizes the importance of assessing the consequences of tasks not being performed rather than just counting tasks. Special conditions and cross-training are also explored as fa…

Chemical Processing Notebook is a new column and associated podcast presenting talking points from various industry experts on a wide range of topics. This first CP Notebook column focuses on the impact PFAS regulations are having on the supply chain, from the upstream chemical producers to the downstream manufacturers using per- and polyfluoroalky…

In this episode, we're tackling the misconceptions around alarm targets and operator workload. Dave Strobhar debunks the myth that hitting a specific alarm target means operators are maxed out. He emphasizes that these targets are tools to assess alarm systems, not workload indicators.By chemicalprocessing

In the evolving world of chemical processing, companies face a formidable challenge as they strive to keep pace with ever-evolving industry demands, develop novel formulations and deliver innovative products to market. Meeting customer needs often requires adjustments to production processes, including new plants, facility expansions and equipment …

The physical properties of hydrogen differ highly from other gases. Plant operators are therefore faced with major challenges due to the necessary adaptations that need to be made. To help us understand the challenges and options available, Chemical Processing spoke with Frank Flow, head of analyzer products and chemical industry at Flexim Americas…

In this podcast episode, Traci and Dave discuss a study that shows advanced process control (APC) can lead to a degradation of operator skills. The study found that after just a week of using APC, there was a 10% loss in skill level, and after two weeks, there was a 50% loss. The data suggests that operators should periodically run the plant withou…

Analytical equipment needs to be robust, reliable and responsive in order to detect change and enable corrective action. It also should be easy to use and provide high uptime. When considering process organics monitoring, there’s a lot to unpack. To help make sense of all the capabilities, Chemical Processing spoke with Amanda Tyndall, senior produ…

Keeping workers safe in hazardous environments requires constant communication. Add to the equation that many locations are also harsh industrial settings means ensuring the right communication equipment is appropriately rated while providing the needed functionality is paramount. To better understand how to select the right equipment, Chemical Pro…

In this final episode of our three-part cybersecurity series with Matt Malone, ICS/OT cybersecurity consultant at Yokogawa, we talk about team strategy and old notions.By chemicalprocessing

Malware programs or endpoint protection programs are great tools. But in the same way that if you're a king sending an army out to battle, you're not going to have your soldiers storming the battlefield in a helmet and their underwear.By chemicalprocessing

Part one of a three-part series aimed at helping you develop a sound cybersecurity plan focuses on assessments and training.By chemicalprocessing

In this episode, we're going to try and get our arms around understanding and addressing risks and how proper equipment and training are key for safe operation in hazardous areas. Joining me to share his expertise is Ryan Brownlee, Global Compliance and Technology Consultant with Pepperl+Fuchs. In that role, he provides guidance in regard to curren…

In this episode of Solution Spotlight Traci Purdum, executive editor of Chemical Processing, speaks with Floyd Baker, vice president of Antea, a global software and services company specializing in asset integrity management software with digital twin. Floyd has been working in the asset integrity management industry for his entire career of over 4…

No longer a warm-fuzzy concept, sustainability is increasingly becoming as good for the bottom line as it is for the environment. To explain how AI-driven solutions that target machine and process health can help with strategy and results, Chemical Processing spoke with James Newman, head of product and portfolio marketing with Augury, a production…

For corrosion-resistant heat-transfer materials in harsh and high-temperature processes, there are additional requirements to consider. To help explain existing and emerging technologies to meet specific process and plant conditions, Chemical Processing spoke with Gregory C. Becherer, senior vice president of Twinsburg, Ohio-based CG Thermal.…

Safety, accuracy and reliability are paramount in the development and testing of fine and specialty chemicals. Add to that the need for regulatory compliance, and it becomes clear that proper tools are needed. To understand how lab instruments can complement the process, Chemical Processing spoke with Mitesh Chhana, Regional Business Manager Lab We…

When it comes to machine maintenance, digital tools promise a lot — from improving safety, meeting production targets and eliminating unplanned downtime to filling skill gaps and regulating supply-chain issues. But simply alerting users to machine malfunctions isn't enough to transform your business. To gain insight, Chemical Processing spoke with …

Supply-chain issues, global competition and the need to deliver high-quality products are challenges facing many chemicals manufacturers today. To meet these challenges, you must keep track of inventory, improve operations, make better products and drive smart, sustainable growth. It’s a tall order but the right tools will help.…

Utilizing maintenance data to make key business decisions results in improved equipment reliability, optimized costs, improved safety, and environmental impacts. However, there are many challenges due to a lack of know-how, resources, and data quality issues. To understand and mitigate those challenges, Chemical Processing spoke with Manjish Naik, …

Efficient conveying solutions that protect workers from hazardous dust, fumes and odors.By chemicalprocessing

Grabbing samples of hazardous chemicals in liquid and gas states is challenging but necessary. Manufacturers rely on quality samples to ensure products specs and operators rely on this equipment to help them grab those samples. But not all sampling platforms are the same.By chemicalprocessing

Solution promises to reduce sensor maintenance, improve process performance, and ensure a safe work environment in the chlor-alkali industry.By chemicalprocessing

While liquid tank level is one of the basic measurements used in process plants, its importance cannot be overstated. Incorrect high level measurements can cause vessels to overflow leading to lost product, a safety hazard or an environmental problem. Incorrect low level measurements can burn out pumps and can cause problems with inventory control.…

The use of surrogate testing is a valuable tool in ensuring that contained dust collectors are meeting several requirements including environmental, employee health and safety and production cleanliness and efficiency. Traci Purdum, executive digital editor of Chemical Processing, spoke with David Steil, pharmaceutical market manager at Camfil Air …

Pardon the pun, but check valves are fairly straight forward -- they ensure flow in only one direction. In most designs, the upstream fluid force pushes a spring-loaded poppet open, allowing flow. An increase in downstream or back-pressure force drives the poppet back into the seat, stopping reverse flow. But their simplicity shouldn’t be taken for…