1. April
2009
Pneumatic
conveying
Page 53
www.che.com
4
capital cost calculations • optimizing pumping systems • achema
Achema
Show Preview
Optimizing
Pumping Systems
Recycling
Cathode Ray Tubes
Temperature
Measurement
& Control
Capital Cost
Calculations
Project
Handover
Vol. 116 no. 4 april 2009
Energy Efficiency
In Steam Systems

2. Performance Fluids from Dow
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Circle 01 on p. 70 or go to adlinks.che.com/23013-01

3. Give your next pneumatic conveyor
the PNEUMATI-CON PLUS advantage: TM
The pneumatic conveying
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efficiency, plus the broad
process experience you need
for seamless integration
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It takes more than a great pneumatic
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process engineering experts who know,
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Which is why you should rely on Flexicon.
Under one roof you will find a
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cyclone separators and blowers, and
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yield maximum efficiency, longevity
and cost effectiveness.
As importantly, you will find experienced
process engineers who draw on
Flexicon’s 10,000+ installations inte-
grating conveyors, screeners, grinders,
crushers, blenders, weigh hoppers,
bulk bag unloaders/fillers, bag/drum
dump stations, and/or storage vessels—
experts who understand how your
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operation of your pneumatic conveyor.
Going the extra mile to outperform
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Circle 04 on p. 70 or go to adlinks.che.com/23013-04

4. Circle 05 on p. 70 or go to adlinks.che.com/23013-05

5. April 2009 In ThIs Issue Volume 116, no. 4
Commentary
5 Editor’s Page
Achema maintains
influence This month,
instead of focusing on
a single comprehensive
www.che.com story or even a two-part
series, our cover high-
lights Achema 2009, an
Cover story
important thread that
34 Cover Story Achema Defies Economic weaves throughout the
Odds Even in a recession year, over issue and beyond. For
180,000 visitors from 100 countries are more, see our Microsite
anticipated at this triennial event www.che.com/achema
neWs
departments
13 Chementator This new crystallizer re-
duced damage to larger crystals; Sonop- Letters ......................... 6
olymerization as a means to manufacture Calendar ................ 9, 11
composite nanoparticles; Reduce process
Crossword Puzzle ....... 38
consumables with this new
separator; A less expensive way Who’s Who ................ 40
to make conductive coatings; Reader
A new standard for viscosity Service page .............. 70
measurement; High-throughput
Economic
screening accelerates glycerol-
Indicators ............. 71, 72
to-chemicals research; A palla-
dium catalyst makes primary
advertisers
amines in aqueous NH3; Optical
fiber sensing gets an NSF boost; Product Showcase...... 64
EPA proposes national reporting system Classified
for greenhouse gases; and more equipment & serviCes Advertising .......... 65–68
24 Newsfront Recycling Cathode Ray 40D-1, 40I-1 Show Preview Advertiser Index ......... 69
Tubes As CRTs become an obsolete form Achema Achema 2009
of video display technology, recycling their (Frankfurt am Main, Coming in may
lead-filed glass is increasingly important Germany; May 11–15),
Look for: Feature Re-
the World’s largest assem-
28 Newsfront Digital Handover Head- ports on Design and
bly of chemical process
aches Electronic project handover has Operation of Gravity
industry professionals is
helped, but standardization with data and Dryers; and Chemi-
approaching. With over
system compatibility remain cal Process Safety;
200,000 visitors and more than 3,500
Engineering Practice
exhibitors filling the exhibition grounds
engineering articles on Optimal
of Messe Frankfurt GmbH, this exhibi-
Cooling Systems for
37 Facts At Your Fingertips Energy Effi- tion and congress on chemical engi-
Coastal Plants; ERP
ciency In Steam Systems This one-page neering, environmental protection and
Packaging for Your
guide explains the importance of efficient biotechnology continues to be the flag-
EPC Contracting Busi-
condensate handling in steam systems ship trade fair for the chemical process
ness; and Treatment of
industries. This show preview contains
42 Feature Report Optimizing Pumping Wastewater in a De-
a cross-section of the products and ser-
Systems Often overlooked, pump system ef- layed Coking Unit; A
vices that will be on display
ficiency makes a dramatic impact on process Focus on Heat Trans-
performance 61 Focus Temperature Measurement & fer; News articles on
Control This three-way valve improves Batch Processing; and
46 Feature Report Calculate Capital Costs
temperature control; Field-ready por- Petroleum Refining;
Quickly Estimating capital costs early can pre-
table temperature monitor features three Facts at Your Finger-
vent wasting money on dead-end projects
Arrows indicate industrial boiler measure-
scales; Get tips on Process Con-
53 Solids Processing Understanding location of wear points
ments for consistent blowdown control; trol; and more
Bends In Pneumatic Conveying This module delivers a wide range of
Systems Despite their apparent capabilities for temperature control; Mea- This month's cover is
simplicity, bends are often sure flowrate and temperature with one composed of pictures
poorly understood and instrument; New infrared sensor offers from Achema 2006.
unless properly designed, improved performance in harsh industrial Photos: Dechema /
Radius bend Blinded lateral
they are potentially problematic environments; and more Helmut Stettin
ChemiCal engineering www.Che.Com april 2009 3

6. Circle 06 on p. 70 or go to adlinks.che.com/23013-06

7. Winner of Eight Jesse H. Neal
Awards for Editorial Excellence
Editor’s Page
Published since 1902
An Access Intelligence Publication
Achema maintains influence
L
PublisHEr Art & dEsiGN
ongtime readers of this magazine may notice that this month’s cover
MikE O’rOurkE dAvid WHitCHEr
theme marks an exception to a rule that has been fairly well estab-
Publisher Art Director/ lished for awhile now. Topics on the cover of Chemical Engineering
morourke@che.com Editorial Production Manager
dwhitcher@che.com
typically reflect one of the practical, how-to articles that we are known
EditOrs
PrOduCtiON for — or at least point readers to an especially timely and lengthy news
rEbEkkAH J. MArsHAll
Editor in Chief MiCHAEl d. krAus roundup article. This time, however, instead of focusing on a single com-
rmarshall@che.com VP of Production & Manufacturing prehensive story or even a two-part series, we highlight an important
mkraus@accessintel.com
dOrOtHy lOzOWski
stEvE OlsON
thread that weaves throughout the issue.
Managing Editor
dlozowski@che.com Director of Production & That thread is Achema 2009, the 29th International Exhibition-Congress
Manufacturing
GErAld ONdrEy (Frankfurt) solson@accessintel.com
on chemical engineering, environmental protection and biotechnology,
Senior Editor
gondrey@che.com WilliAM C. GrAHAM which will take place next month (May 11–15) at the colossal fairgrounds
kAtE tOrzEWski
Ad Production Manager in Frankfurt, Germany. Notably contrary to what one would expect for a
bgraham@che.com
Assistant Editor
MArkEtiNG
trade show in this economy, Achema does not show signs of unraveling.
ktorzewski@che.com
HOlly rOuNtrEE
Chemical Engineering’s cover policies aside, Achema is in no way a new
suzANNE A. sHEllEy
Contributing Editor Marketing Manager phenomenon to this magazine or to the global chemical process industries
hrountree@accessintel.com
sshelley@che.com (CPI) that it serves. The first Achema was held in 1920 in Hanover, with 75
AudiENCE
COrrEsPONdENts
dEvElOPMENt exhibitors. Initially touring different German cities for a short period, Achema
CHArlEs butCHEr (U.K.)
sylviA siErrA has long been staged in Frankfurt on a frequency of once every three years.
cbutcher@che.com
Senior Vice President, Over time, Achema has grown substantially and is on course to attract
PAul s. GrAd (Australia) Corporate Audience Development
pgrad@che.com ssierra@accessintel.com 180,000 visitors this year — slightly more than the previous Achema did
tEtsuO sAtOH (Japan) JOHN rOCkWEll in 2006 under much better economic circumstances. The size of the event
Vice President,
tsatoh@che.com
Audience Development Chemical
is truly remarkable. Dechema e.V., the show’s organizer, expects around
JOy lEPrEE (New Jersey) jrockwell@accessintel.com 4,000 exhibitors to fill 140,000 m2 of net exhibition space — that is equiv-
jlepree@che.com
GErAld PArkiNsON
lAuriE HOfMANN alent to more than half of the combined floor area of the Empire State
Audience Marketing Director
(California) gparkinson@che.com lhofmann@Accessintel.com Building here in New York. Meanwhile, Achema continues its trend toward
EditOriAl tErry bEst becoming increasingly global, with around 46% of exhibitors coming from
AdvisOry bOArd Audience Development Manager
tbest@accessintel.com
outside Germany, compared to 44% in the year 2006.
JOHN CArsON
Jenike & Johanson, Inc. GEOrGE sEvEriNE That said, it is easy to wonder what is holding Achema together when the
dAvid diCkEy Fulfillment Manager CPI’s travel budgets and other expenditures are reportedly being cut. That
gseverine@accessintel.com
MixTech, Inc.
CHristiE lAMONt
anomaly is the subject of our Newsfront on p. 34, which points out — among
MukEsH dOblE List Sales, World Data 561-393-8200 other things — that Achema has a reputation for being “the place” to showcase
IIT Madras, India
HENry kistEr
CONfErENCEs new technologies. See our Achema Show Preview (p. 40) for a brief crossection
Fluor Corp. dANA d. CArEy of the products to be unveiled there (also see March, p. 40, for Part I).
Director, Global Event Sponsorships
trEvOr klEtz dcarey@chemweek.com Even as prevalent as the Achema theme is in this issue, it is only the
Loughborough University, U.K.
PECk siM tip of the iceberg when it comes to our coverage of the event. Chemical En-
GErHArd krEysA
DECHEMA e.V.
Senior Manager,
Conference Programming
gineering delivers Achema-related news across our print and online plat-
rAM rAMACHANdrAN psim@chemweek.com forms leading up to, during and after the show. The central clearinghouse
BOC bEAtriz suArEz for this content is our Achema Microsite (www.che.com/achema), which
Director of Conference Operations
iNfOrMAtiON
bsuarez@chemweek.com has been live since February. A comprehensive collection of Achema show
sErviCEs
rObErt PACiOrEk
COrPOrAtE news, new product summaries, exhibitor information and useful visitor
Senior VP & Chief Information Officer stEvE bArbEr links, this online show guide is a convenient resource not only for Achema
rpaciorek@accessintel.com VP, Financial Planning & Internal Audit
sbarber@accessintel.com
visitors but for all chemical engineers who are simply curious about the
CHArlEs sANds
Senior Developer briAN NEssEN important trends that are emerging in the CPI.
Web/business Applications Architect Group Publisher Of course, during the show, Chemical Engineering editors will once again
csands@accessintel.com bnessen@accessintel.com
be onsite to produce the official Achema Daily, in cooperation with Vogel
HEAdquArtErs
Business Media GmbH. And, our Achema review in the July issue will round
110 William Street, 11th Floor, New York, NY 10038, U.S.
Tel: 212-621-4900 Fax: 212-621-4694 up the highlights of the show and summarize the many
EurOPEAN EditOriAl OffiCEs innovations that we witness there.
Zeilweg 44, D-60439 Frankfurt am Main, Germany The point is, Achema’s front and center status in
Tel: 49-69-2547-2073 Fax: 49-69-5700-2484
this magazine might indeed be rare, but its influence
CirCulAtiON rEquEsts:
Tel: 847-564-9290 Fax: 847-564-9453
is ongoing. For the connections that we make there,
Fullfillment Manager; P.O. Box 3588, ourselves, go a long way toward achieving two chief,
Northbrook, IL 60065-3588 email: clientservices@che.com
longterm goals: cultivating good sources for practical,
AdvErtisiNG rEquEsts: see p. 70
how-to articles and keeping you informed of what is
For photocopy or reuse requests: 800-772-3350 or info@copyright.com
For reprints: chemicalengineering@theygsgroup.com happening in and affecting the CPI. ■
Rebekkah Marshall
ChemiCal engineering www.Che.Com april 2009 5

8. Letters
Solar plant construction
Thank you for your recent article, Solar’s Second Com-
ing, in March (pp. 18–21). I completely enjoyed it. Your
information was relevant and quite well presented.
Perhaps you might consider a follow-up story on
how the components and their materials of construc-
tion are affecting solar plant efficiency and construc-
tion costs. The chemistry and metallurgy that are
being used in struts, frames, and storage devices are,
in many ways, as interesting as the plants themselves.
Again, congratulations on a terrific article.
Brian Courtney, Senior PR Executive
Schubert Communications, Inc., Downingtown, Pa.
Hydraulic Institute seeks input
on ANSI pump standards
The Hydraulic Institute (HI; Parsippany, N.J.; www.
pumps.org), under the approval of the American Na-
tional Standards Institute (ANSI; Washington, D.C.;
www.ansi.org), is seeking qualified individuals in
North America to participate in the review process for
the draft of two updated standards:
1. Standard ANSI/HI 4.1-4.6, Sealless Rotary Pumps
for Nomenclature, Definitions, Application, Opera-
tion and Test. This standard covers the unique
features of sealless rotary pumps and includes
sections on types and nomenclature; definitions;
design and applications; installation, operation,
and maintenance; and test. Because of the variety
of rotary pump configurations available and the
broad range of applications, familiarization with
Circle 57 on p. 70 or go to adlinks.che.com/23013-57
Hydraulic Institute Standards ANSI/HI 3.1–3.5
Rotary Pumps for Nomenclature, Definitions, Ap-
plication and Operation and ANSI/HI 3.6 Rotary
Pump Tests is recommended.
2. ANSI/HI 5.1-5.6, Sealless Rotodynamic (Centrifu-
gal) Pumps for Nomenclature, Definitions, Applica-
tion, Operation and Test. This standard applies to
canned motor pumps and magnetic drive pumps.
Excluded from the scope of products are submersible
wastewater pumps. The standard includes types and
nomenclature; design and application; installation,
operation and maintenance; and test.
Individuals and organizations directly and materi-
ally affected by either standard are asked to contact
HI. These parties include pump users and specifiers,
producers, standards developers, government agencies,
and general interest groups. HI is currently assem-
bling a canvass list of all parties interested in review-
ing the drafts. These lists will be submitted to ANSI in
order to meet its open canvass requirements.
To participate in the ANSI/HI canvass, contact Karen
Anderson, administrator, Technical Affairs, at kanderson
@pumps.org or (973) 267-9700 x 23.

9. Centrifuges
Filters
Dryers
Systems
-Maffei
Krauss fuges
Centri ryers
D
Filters, d
an
s
System
I want
When you choose KMPT and our Krauss-Maffei Centrifuges, Filters and Dryers,
EMA in you will realize the quality gained from tradition in innovative equipment design
at ACH y.
Visit us rt, German 3-E16 and manufacturing. As we have done for more than 80 years, our engineers
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We areg you. Trials at our test center ensure your decision for safety, reliability and efficiency
meetin of your process application. Free-admission vouchers for Achema are available
at www.kmpt.com/active or per mail to achema@kmpt.com
Circle 07 on p. 70 or go to adlinks.che.com/23013-07

10. mighty powerful
With Experion LS even small plants can carry a heavy load.
Improve cycle time, quality and compliance with the power of a distributed
control system delivered in a compact package. Honeywell provides process
manufacturers of all sizes with optimum productivity and profitability.
With powerful batch features, Experion LS helps small sites better respond
to market changes and increase process uptime without the cumbersome
engineering and lifecycle support of traditional PLC-based solutions.
Let the process control experts help you transform your business with an agile system designed to
reduce lifecycle costs and improve process efficiencies. 
To learn more about Experion LS, please call 1-877-466-3993 or visit 
Circle 09 on p. 70 or go to adlinks.che.com/23013-09 /© 2009 Honeywell International, Inc. All rights reserved.

11. Calendar
NORTH AMERICA
Residuals and Biosolids 2009. Water Environment Westfalia Separator ®
Federation Specialty Conferences (Alexandria, Va.).
Phone: 703-684-2400, ext. 7739; Web: wef.org
caretechnology
Portland, Ore. May 3–6
22nd Annual Technical Conference & Exhibition.
American Filtration and Separations Society (Richfield,
Minn.). Phone: 612-861-1277; Fax: 612-861-7959; Web:
afssociety.org/spring2009/
Bloomington, Minn. ay 09
May 4–7 11. - 15. M
ACHEMA
- G 22
Stand D 13
World Innovation Forum. HSM Group (New York, N.Y.). Hall 4.0 |
Phone: 866-711-4476; Web: hsmglobal.com/us
New York, N.Y. May 5–6
Engineered
Plastics in Underground Pipes 2009. Applied Market
Information (AMI) LLC (Reading, Pa.). Phone: 610-478-
0800; Web: amiplastics-na.com/events/
Orlando, Fla. May 6–7
with Care
19th Annual Joint ISA POWID/EPRI Controls and
Instrumentation Conference, and 52nd Annual
POWID Division Sympostium. ISA (Research Triangle
Park, N.C.). Phone: 919-549-8411; Web: isa.org/powersymp
Chicago, Ill. May 12–14 Protecting people and the environment while
boosting separation efficiency and reducing
11th Annual Electric Power Conference & Exhibi- operating costs – Westfalia Separator caretechnology
tion. Trade Fair Group (Houston, Tex.). Phone: 832-242- combines these parameters in a single concept.
1969, ext. 306); Web: electricpowerexpo.com
Rosemont, Ill. May 12–14 Our separators and decanters, developed specially
for the chemical industry, ensure safe production.
IETC 2009: 31st Industrial Energy Technology They fulfil all applicable explosion proof regulations
Conference. Texas A&M University, Energy Systems
and are rated for overpressure conditions.
Laboratory (College Station, Tex.); Phone: 979-847-8950;
Web: http://ietc.tamu.edu
New Orleans, La. May 12–15 Profitable production is assured thanks to design
features such as the special corrosion-resistant
2009 BIO International Convention. BIO Interna- lining of the separator bowls and the option of
tional (Washington, D.C.). Phone: 202-962-6655; direct drive.
Web: convention.bio.org
Atlanta, Ga. May 18–21 Safety and productivity in ideal combination –
Westfalia Separator caretechnology for the chemical
19th Annual Fugitive Emissions/Leak Detection industry.
and Repair (LDAR) Training and Symposium. The
International Society of Automation (Research Triangle
Park, N.C.). Phone: 919-549-8411; Web: isa.org/ldar
You will find further information at:
Austin, Tex. May 19–22
www.westfalia-separator.com, SMARTSearch Code 2505CE
55th International Instrumentation Symposium.
The International Society of Automation (ISA; Research
Circle 08 on p. 70 or go to
Triangle Park. N.C.). Phone: 919-549-9418; Web: isa.org/iis adlinks.che.com/23013-08
League City, Tex. June 1–5
Human Error Prevention (a) and Root Cause Anal-
ysis (b) Seminars. High Technology Seminars (Cold GEA Westfalia Separator Process GmbH
WSPC-2-50-005
Spring, N.Y.). Phone: 845-265-0123; Web: Werner-Habig-Straße 1 · 59302 Oelde (Germany)
hightechnologyseminars.com Phone +49 2522 77-0 · Fax +49 2522 77-2828
ws.process@geagroup.com · www.westfalia-separator.com

12. Circle 10 on p. 70 or go to adlinks.che.com/23013-10

13. FP0.C.GB
Calendar
Albuquerque, N.M. June 9–10 (a), and June 11–12 (b)
Atlantic Design & Manufacturing Show. Canon Com-
munications LLC (Los Angeles, Calif.). Phone: 310-445-
4200; Web: atldesignshow.com Visit us!
New York, N.Y. June 9–11 ACHEMA 2009
Frankfurt am Main,
AWWA Annual Conference and Exposition 2009. Germany
American Waterworks Assn. (Denver, Colo.). Phone: 303- 11 - 15 May 2009
347-6140; Web: awwa.org Hall 3.0, Stand L20 - L21
San Diego, Calif. June 14–18
Honeywell Users Group Americas Symposium.
Honeywell Automation & Control Solutions (Phoenix,
Ariz.). Phone: 877-466-3993; Web: honeywell.com
Phoenix, Ariz. June14–19
13th IACIS International Conference on Surface
and Colloids, and 83rd ACS Colloid and Surface
Symposium. International Assn. of Colloid and Interface
Scientists (Delft, Netherlands), American Chemical
Society — Division of Colloid and Surface Chemistry, and
NSF Industry/University Center for Surfactants at Co-
lumbia University (New York, N.Y.); Phone: 203-569-7909;
Web: innoresearch.net
New York, N.Y. June 14–19
Recycling Metals from Industrials Waste. Colorado
School of Mines (Golden, Colo).; Phone: 303-273-3321;
Web: mines.edu/outreach
Golden, Colo. June 23–25
Conveying Palletizing Packaging
EURopE
Nanofair 2009. VDI Wissensforum GmbH (Düsseldorf,
Germany). Phone: +49 (0) 211 62 14 201; Web:
nanofair.com
Dresden, Germany May 26–27
BEUMER solutions for
Electronics & Battery Recycling 2009. ICM AG
(Birrwil, Switzerland). Phone: + 41 (0) 62 785 1000; Fax:
the chemical industry.
+ 41 (0) 62 785 1005; Web: icm.ch
Toronto, Ont. June 24–26
Efficient. Safe.
17th European Biomass Conference & Exhibition.
ETA-Renewable Energies (Florence, Italy) and WIP-
Renewable Energies (Munich, Germany); Phone: +39 055
500 2280; Fax: +39 055 573 425; As a leading international manufacturer of
Web: conference-biomass.com intralogistic solutions for the conveying, palletizing
Hamburg, Germany June 29–July 2 and packaging equipment segments, we know
every aspect of your products and their specific
properties. This expertise flows into the design
ASIA & ElSEWHERE and construction of all our plants and systems
23rd International Activated Carbon Conference for the chemical industry. See for yourself. We
and Courses. PACS Testing and Consulting (Coraopolis, look forward to your visit!
Pa.). Phone: 724-457-6676; Fax: 724-457-1214; Web:
pacslabs.com
Circle 11 on p. 70 or go to
Johannesburg, South Africa May 26–27 ■ adlinks.che.com/23013-11
Suzanne Shelley
www.beumer.com

14. Too good to be true? We’ll let you decide. Try the AT9000 before you
buy. We think that you’ll be impressed with its consistent performance
from day one to year ten, thrilled by its ease of customization, and
pleasantly surprised by the window sticker.
The Yamatake AT9000 Advanced Transmitter
Reliability you need. Performace you want. Pricing you crave.
Circle 12 on p. 70 or go to adlinks.che.com/23013-12
888-262-4639
YamatakeAmerica.com

15. Edited by Gerald Ondrey April 2009
Vapor
Calibration-free pH
This new crystallizer reduces Crystallizer Fines destruction
The world’s first con-
damage to larger crystals Steam
tinuously self-calibrating ph
measurement system was
Fines previewed at the interphex
W ith the exception of Oslo-type crystalliz-
ers, the main commercial crystallizers
are agitated systems that use an agitator Small Condensates
show in new York last month
by Sensorin (Burlingame,
crystals Calif; www.sensorin.com).
[agitated tank or draft-tube baffle (DTB)] or according to the manufac-
a circulation pump [forced circulation (FC) turer, all currently available
crystallizers]. In such systems, however, ph sensors including glass,
large crystals become damaged by the pump optical and ion-selective field
Small & large
or impeller, which leads to the generation crystals effect transistors (iSFeT)
of fines, says Michel Malfand, president of Larger
require calibration, whereas
Crystal Evap consult (Draveil, France). crystals Sensorin’s approach, which
Steam is internally referenced and
As a result, FC units typically have an
based upon amperometric
elutriating leg, and most DTBs have
Heater ph sensing, does not. This is
some type of “fines killer”, he says. Mixing device
a plus for online monitoring
Malfand has patented a new crystal- Feed
of ph-sensitive applications.
lizer (diagram) that is based on a differ- Condensates The Sensorin solid-state
ent hydraulic concept, whereby only the me- tals with a d50 of 500 microns, compared to design combines two elec-
dium-sized crystals are in contact with the dispersed crystals with a d50 of 200–250 mi- trodes onto a proprietary
agitating device; the larger crystals are indi- crons produced in conventional crystallizers, substrate on the same
rectly circulated without contact. To increase says Malfand. Because fewer fines are pro- probe’s surface. Both elec-
the particle size, the system is also equipped duced, there is less recycled material from trodes, therefore, contact
the aqueous solution to be
with a leg and, if necessary, a fines killer. the dryer, the air treatment and the screen.
analyzed. The reference
A pilot crystallizer has been constructed As a result, the new crystallizer is expected
electrode is a ph-insen-
capable of producing 20–40 kg/h of crystals to save energy and capital costs, he says. sitive redox couple and
with a water evaporation rate of 40–120 And because there is no pump or agitator, its potential is a constant
kg/h. The hydraulic concept has been vali- scaleup is very easy, adds Malfand. signal at a constant poten-
dated, achieving improved crystal size dis- Last month, the firm started tests for a po- tial in solution. The mea-
tribution and lower coefficient of variation tential customer; the results of the test could surement electrode is a
(CV). In tests performed with product “A”, lead to the construction of a crystallizer with ph-sensitive redox couple
the crystallizer produced homogeneous crys- a 40,000 metric ton per year (m.t./yr) capacty. and its potential varies as
a function of hydronium ion
concentration. The sensing
Sonopolymerization as a means is performed by measuring
to manufacture composite nanoparticles (Continues on p. 14)
M any methods have been developed
for the encapsulation of “active”
materials within a carrier nanopar-
nanoencapsulation of magnetite nano-
particles within host latex particles.
The team says sonochemical free-
fusional forces in ways that individual
nanoparticles will not.” This is an impor-
tant factor in chemical processes using
ticle, such as a polymer. These compos- radical-polymerization reactions can be high-gradient magnetic separations.
ite structures can be used in many bio- achieved without chemical initiators, The process starts with magnetite
medical, cosmetics, and food processing and that fast polymerization rates are particles dispersed in the monomer
applications for the controlled release of obtained with a relatively high percent- phase. Water and sodium dodecyl sul-
pharmaceuticals, neutraceuticals, and age of monomer-to-polymer conversion. fate (SDS) is added to the phase. The
flavors. However, most of the proposed The particles exhibit excellent colloidal liquid mixture is sonicated (20 kHz, 8 W/
encapsulation methods developed so far stability and strong magnetic proper- cm2) for 20 s, which leads to the forma-
involve multiple steps or complex prepa- ties, and are of the desired size to be tion of SDS-stabilized monomer droplets
ration. Now a team from the School of technologically relevant, according to containing magnetite particles. Further
Chemistry, University of Melbourne the researchers. The composite beads sonication for 50 min leads to SDS stabi-
(Australia; www.unimelb.edu.au) and prepared by the team “will retain the lized polymer particles containing mag-
the Dept. of Chemical Engineering, Mas- superparamagnetic properties of their netite particles. The researchers believe
sachusetts Institute of Technology (MIT; small constituent Fe3O4 nanoparticles, this technique can be applied to a range
Cambridge, Mass.; www.mit.edu), has yet have sufficient magnetic content of polymers, and are currently investi-
developed a “one-pot” sonochemical pro- that they will respond to magnetic field gating the synthesis of polymers sensi-
cess using ultrasound at 20 kHz for the gradients to overcome counteracting dif- tive to temperature and pH.
Note: For more information, circle the 3-digit number
on p. 70, or use the website designation. ChemiCal engineering www.Che.Com april 2009 13

16. (Continued from p. 13)
C hementato R
the potential difference be-
tween the current peaks for the
1 2 3 4 two reagents. Since the peak
Upperflow potential of both electrodes is
Floating layer
used with every measurement,
Reduce process consumables the sensor is inherently self-
calibrating. This Continuously
with this new separator Self-Calibrating Sensor (CSC
Sensor) design is independent
of temperature, pressure and
A queous Recovery Resources, Inc. (ARR;
Bedford Hill, NY; www.suparator.com),
has developed the Suparator, an oil/water Bottom valve Underpressure
other variables that can inter-
fere with other ph systems.
separation system that involves no moving Underflow
Sonocrystallization
parts or media, for low operational costs
Syrris ltd. (royston; www.
and minimal maintenance. The separator and chemicals re-enter the water flow (3).
syrris.com) has launched
(diagram) is based on the Bernoulli effect, Finally, the upper fraction of the floating the atlas Sonolab System in
whereby increased stream velocity in a fluid layer gets skimmed off, isolating pure oil for collaboration with prosonix
results in internal pressure reduction, which refining or storage (4). ltd., (oxford, both U.K.; www.
enables liquids of different specific gravi- This technology enables desired chemi- prosonix.co.uk). The auto-
ties to be separated. A number of valves are cals to stay in the aqueous medium and not mated system combines the
mounted across the fluid channel such that get separated with the oil, making it ideal atlas jacketed-reactor platform
the major part of the flow passes underneath for removing thin oil films from valuable with prosonix’s Sonolab ultra-
and a smaller portion passes overhead. Sev- mixtures and solutions. By reusing the re- sound technology, enabling the
eral wings are used to progressively shear sulting process fluids and allowing oils to be reproducible control of crystal-
lizations, and allows selectivity
off more oil and reduce water content. Dirt recovered and reused, process consumables
of parameters such as particle
and other unwanted foreign objects also get are potentially reduced by 50%, compared to size, shape, crystallinity and
removed before they settle into the water. conventional separators, says ARR. polymorphism. The system can
In the first step, water and oil enter a com- Since the system was commercialized a also be used for sonomilling
partment (1), from which only water gets few months ago, several large-scale units and sonochemistry.
sucked out (2). The remaining oil becomes have been sold. ARR is next looking to use
concentrated into a thick floating layer, but the Suparator in the extraction of oil from Energy-saving burner
still contains some water and chemicals. The Canadian oil sands, which are very thick last month, Dürr environmen-
oil becomes further concentrated as water and difficult to separate. tal and energy Systems (Stutt-
gart, germany; www.durr.com)
launched the Tarcom V gas
A less expensive way to make conductive coatings burner, which is said to reduce
energy consumption in ther-
C ambrios Technologies Corp. (Sunnyvale, strates. The coating can be formed at room mal air oxidizer (Tar) systems.
Calif.; www.cambrios.com) has formed temperature using standard coating pro- The burner can be retrofitted
a strategic partnership with Chisso Corp. cess equipment, such as slot die, gravure into existing Tar oxidizers.
Tarcom V is the product of
(www.chisso.co.jp) and Sumitomo Corp. and spin coaters, instead of sputtering. The
a series of burner develop-
(both Tokyo; www.sumitomocorp.co.jp) for coated film is then soft baked at a low tem- ments, which started with the
commercialization of Cambrios’ first prod- perature for a short time to achieve best so-called cone burner, and
uct, ClearOhm coating material. Targeted performance characteristics. further refined into the swirl
for the liquid crystal display (LCD) market, ClearOhm coatings have been found to burner, and has now culmi-
ClearOhm is seen as a solution to some of perform better than standard transparent nated in a swirl burner with a
the problems with the currently available conductors in many applications. For exam- hollow cylindrical flame. This
transparent conductive coatings that are ple, this novel coating has better transmis- flame geometry — similar
made from Indium tin oxide (ITO) and other sion than standard transparent conductive to a rotating hollow cylinder
conductive oxides. oxides (TCO) in a wide range of conductivi- — achieves a high mixing ef-
ficiency, resulting in a better
Transparent conductive materials are ties. ClearOhm coated films are also more
temperature distribution in the
widely used for displays, touch panels, flexible and far less prone to cracking. combustion chamber, which
solar cells and other applications. Coatings Another consideration is that in most ap- in turn leads to “significant”
of these materials, such as ITO, are depos- plications, transparent conductive layers are energy savings and improved
ited using expensive, energy-consuming patterned and so require additional process- emissions, says the company.
vacuum-sputtering processes. The market ing steps. ClearOhm can be printed directly,
has been interested in finding a replace- eliminating the need for costly patterning Slow-release pesticides
ment for ITO to eliminate the high cost of equipment and additional acids and other Scientists at the institute of
processing involved. chemicals used in the patterning process. natural resources and agrobi-
Cambrios’ technology consists of a dis- Cambrios expects commercial sales of ology of the Spanish national
persion of metallic nanowires in a solvent, ClearOhm coatings in the touch-panel mar- research Council (madrid;
which is typically water, that has a viscos- ket starting in 2009, with future plans for www.csis.es) have developed
ity and surface tension suitable for most commercialization in the LCD and thin-film
(Continues on p. 16)
wet-processing coating equipment and sub- solar markets.
14 ChemiCal engineering www.Che.Com april 2009

17. Your process must remain on target
at a certain temperature.
Can your mixing valves keep it there?
For worry-free heat exchanger control, choose the Fisher® GX 3-way
valve from Emerson. It provides accurate, constant control of
temperature for either mixing or splitting service. And its robust,
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temperature fluctuations than the Fisher GX 3-way valve. Learn more
at www.Fisher.com/gxCE or contact an Emerson sales office.
The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2008 Fisher Controls International LLC MU35-CD197

18. C hementato R (Continued from p. 14)
a method to encapsulate and
Moving piston in measurement chamber
slowly release pesticides as a
A new standard for Electromagnetic coils
Internal temperature probe RTD
means to prevent leaching and
volatization of the substances
viscosity measurement into the environment. The
pesticide is encapsulated in
T he American Society of Testing
Materials (Conshohocken, Pa.;
www.astm.org) has developed a
are capable of taking viscosity mea-
surements of fluids much more
frequently than older capillary-
lecithin liposomes or vesicles,
which in turn are fixed onto
the surface of clay. The final
new standard for measuring vis- tube viscometers. They also product is a powder that can
cosity: ASTM D 7483-08, Determina- use a smaller sample size (volume of be dispersed in water. adsorp-
tion of Dynamic and Kinematic Vis- less than 5 mL with a typical solvent tion to the clay prevents the
cosity of Liquids by Oscillating Piston volume of less than 10 mL) than rota- active compound from being
washed away, yet enables the
Viscometer (OPV). The new ASTM tional or vibrational viscometers, says
slow release of the pesticide
method is part of a brand new product Arthur Hindman, executive vice-presi- as needed. The researchers
line to be launched this month by Cam- dent of Cambridge Viscosity. believe the method can be ap-
bridge Viscosity (Medford, Mass.; www. The new test method can be particularly plied in other areas, such as
cambridgeviscosity.com). suitable for many petroleum products and mosquito repellents.
OPVs are driven by two coils that move lubricants for bearings, gears, compressor
a piston back and forth magnetically at a cylinders, hydraulic equipment, fine PFOA alternative
constant force (diagram). Cambridge Viscos- and general chemicals and coatings, Cerealus holdings, llC (wa-
ity’s patented circuitry analyzes the piston’s where proper viscosity is important terville, maine; www.cerealus.
two-way travel time to measure and con- f o r product performance. It covers the com) has developed a non-
trol absolute viscosity. OPVs allow viscosity measurement of dynamic viscosity and deri- toxic, bio-based chemical
measurement and control of a broad range vation of kinematic viscosity of liquids, such replacement for fluorinated
of fluids including those that are transpar- as new and in-service lubricating oils. The compounds, such as perfluo-
ent, translucent and opaque. The measure- test method is applicable to Newtonian and rooctcanoic acid (pFoa), used
ment function of the viscometer is fully au- non-Newtonian liquids, covering dynamic in food packaging and food-
tomatic and maintains a continuous fresh viscosities of 0.2 to 20,000 cP at tempera- (Continues on p. 20)
sample while under test. Oscillating pistons tures of –40 to 190°C.
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Circle 14 on p. 70 or go to adlinks.che.com/23013-14
16 ChemiCal engineering www.Che.Com april 2009

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Circle 15 on p. 70 or go to adlinks.che.com/23013-15

20. C hementato R
High-throughput screening accelerates glycerol-to-chemicals research
A rkema (Colomes, France; www.
arkema.com) and hte (Heidelberg,
Germany; www.hte-company.de) have
using conventional testing equipment,”
says Jean-Luc Dubois, scientific direc-
tor at Arkema.
the first step; this not only extends the
life of the catalyst, but also significantly
reduces the production of some byprod-
successfully concluded a research col- Arkema already has a number of pat- ucts, says Dubois.
laboration aimed at identifying new ents covering this glycerol-to-chemicals Glycerol conversions of 100% are easy
catalysts for the conversion of glycerol technology. In the process, glycerol first to achieve, and several families of cata-
— a byproduct of biodiesel production undergoes an intramolecular dehydra- lysts can lead to selectivities of at least
— to acrolein (2-propenal) and acrylic tion to acrolein using a solid acid cata- 70%, says Dubois. The acid strength of
acid. The collaboration, which started lyst. Acrolein is then further oxidized to the catalyst is one of the key param-
last year, utilized hte’s proprietary par- acrylic acid with the same catalyst, or in eters, he adds. Arkema may build a
allel testing technology to explore and a separate reactor. The reaction takes demonstration plant within two to four
evaluate suitable catalysts by means of place in the gas phase at 300°C and near years. This will only make sense if the
high-throughput experimentation. “By atmospheric pressure. Although glycerol product can be made at the same cost
using this approach, we have produced dehydration does not require another re- as current technology, but with a lower
results in a matter of months; this nor- agent, a major innovation (patented by carbon footprint — something Arkema
mally would have taken over two years Arkema) has been to add oxygen during is now investigating, says Dubois.
A palladium catalyst makes primary amines in aqueous NH3
P rimary amines are made in high
yield by a palladium-catalyzed al-
lylic amination reaction developed by
source — the first time this has ever
been achieved, disproving a 30-year
old theory that allylic amination using
rahydrofuran (THF) solvent. No reaction
occurred when using NH3 gas as the
nitrogen source; but when switching to
Shu Kobayashi, a chemistry professor aqueous ammonia was impossible. aqueous NH3, the researchers obtained
at the University of Tokyo (Japan; www. Kobayashi discovered the method 71% secondary amine and 14% primary
chem.s.u-tokyo.ac.jp.). The reaction when trying to perform allylic amina- amine. Kobayashi speculates that the pri-
uses aqueous ammonia as the nitrogen
SpencerACHEMAad7x4.875final:Layout 1 3/18/09 1:22 PM Page 1 in tet-
tion of 1,3-diphenyl allyl acetate (Continues on p. 20)
Specials are
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In the process Spencer applies more than 115 years of industry
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Circle 16 on p. 70 or go to adlinks.che.com/23013-16
18 ChemiCal engineering www.Che.Com april 2009

21. Circle 17 on p. 70 or go to adlinks.che.com/23013-17

22. (Continued from p. 16)
C hementato R grade paper. The patented
coating additive, called hold-
Optical fiber sensing gets an NSF boost out, is made from a byproduct
of corn, and is a water-based
L ast January, Chiral Photonics, Inc. (Pine toring, industrial furnaces (such as smelters) formulation that is grease and
Brook, N.J.; www.chiralphotonics.com) was and concentrated solar power. oil-resistant, making is suitable
Sensor gratings are fabricated by twisting a for food packaging in the fast-
awarded $500,000 in a Small Business Tech-
food industries. pFoa, which
nology Transfer Phase II grant from the Na- glass fiber into a helix as it is passed through a
is used in similar applications,
tional Science Foundation (NSF; Washington, microheating zone. The resulting optical fiber, has come under increased
D.C.). The grant will be used to develop a new tradenamed Helica, has unique optical prop- scrutiny over its potential tox-
optical-fiber-sensor platform capable of mea- erties. For example, characteristic dips in the icity, and was classified as a
suring temperature, pressure, strain axial grating’s optical transmission spectrum shift “likely human carcinogen” in
twist, liquid levels and other variables. The to the red by about 1.3 nm as the temperature 2006 by epa, which has com-
company has already started commercial- increases by 100°C — the property that is ex- menced programs to eliminate
izing a temperature sensor — based on the ploited for high-temperature sensing. pFoa production by 2015.
patented chiral grating technology — that Fiber optic sensors are immune to electro-
is capable of measuring temperatures up to magnetic interference, have fast response Making H2 from H2O
1,000°C with ±1% accuracy, says business times, can be remotely operated and pose no Scientists at the max planck
development manager Saul Felman. Since electrical ignition hazard. Because the grat- institute of Colloids and inter-
then, the device has found applications in pe- ings can be implemented in any fiber, ra- faces (potsdam-golm, ger-
troleum refining (fractional distillation pro- diation and chemically resistant fibers are many; www.mpikg-golm.de)
cessing and combustion), oil borehole moni- being developed. have discovered that carbon
nitride acts as a photocata-
Palladium Catalyst (Cont. from p. 18) lyst for splitting water into h2.
been achieved with other allyl substrates. In
Besides being less expensive
mary amines form first, which subsequently addition, asymmetric synthesis of optically than alternatives (such as
undergo a further amination to form the sec- active allyl-amine have been performed inorganic semiconductors
ondary amine. This secondary reaction can be with 71% yield and stereo-selectivity of 87% doped with pt), the carbon
suppressed by using dioxane instead of THF using a palladium catalyst with BINAP nitride is stable over a wide
as solvent, producing 71% primary amine. [2,2'-bis(diphenylphosphino)-1,1'-binaph- ph range. The next step is to
Primary amine yields of 71–85% have also thyl] ligand. improve the efficiency. ❏
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20 ChemiCal engineering www.Che.Com april 2009
CAS-176A.indd 1 11/24/08 4:02:57 PM

23. Materials | Development | Solutions
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Circle 19 on p. 70 or go to adlinks.che.com/23013-19

24. C hementato R
Cut installation costs in half with this orifice flowmeter
A BB Instrumentation (Warminster,
Pa.; www.abb.com/instrumentation)
has cut the cost of installing orifice-plate
OriMaster installation is sim-
plified by its wafer-design, orifice-
carrier assembly, enabling it to be fitted
in line sizes from 1 to 8 in.
(DN25 to DN200) and pres-
sures up to 1,450 psi (100 bars).
flowmeters by up to half with the launch into an existing space between standard The OriMaster combines all major
of its OriMaster compact orifice DP flow- pipe flanges. Because incorrect central- components needed for installa-
meter. The latest in the company’s Flow- izing of orifice devices can cause ad- tion in one assembly, thereby
Master range, the OriMaster comes fully ditional metering errors of 3%, the eliminating the need for users
factory configured and pressure tested, OriMaster comes with a centering to source and install a separate
solving many of the problems associated tool to ensure correct placement in manifold, transmitter and im-
with sizing, selection, installation and the pipeline. pulse piping, typically cutting
operation of conventional orifice-plate The flowmeter is suitable for clean the cost to install and commis-
installations, says ABB. liquids, gases and steam applications sion by up to 50%, says ABB.
EPA proposes national reporting system for greenhouse gases
T he U.S. Environmental Protection
Agency (EPA, Washington D.C.) plans
to set up the first U.S. national system
better protect our health and environ-
ment,” says Administrator Lisa Jackson.
Under the initial proposal, the report-
mit their first annual reports in 2011,
for calendar year 2010.
The proposed rule will be published
for reporting emissions of CO2 and other ing requirements would apply to suppli- shortly in the Federal Register, after
greenhouse gases. The proposal marks the ers of fossil fuel and industrial chemi- which there will be a 60-day comment
first step toward a program for climate cals, manufacturers of motor vehicles period, including two public hearings,
control. “Through this new reporting we and engines, and facilities that have before the rule is finalized. The report-
will have comprehensive and accurate greenhouse gas emissions of 25,000 ing requirements will cost industry
data about the production of greenhouse m.t./yr or more. Most (except for vehicle $160 million in 2011 and $127 million in
gases . . . a critical step toward helping us and engine manufacturers) would sub- subsequent years, estimates the EPA. ■
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25. Circle 21 on p. 70 or go to adlinks.che.com/23013-21