1. February
2009 HEAT
EXCHANGERS
Page 40
www.che.com
2
nanotechnology • heat exchangers
Page 34
Eye-and-Face
Vol. 116 No. 2 February 2009
Protective Equipment
Oil From Sand Flow Measurement Control Water Reuse Systems
Facts at Your Fingertips: Selecting a Conveyor
Pipe Sizing
01_CHE_021509_COV.indd 1 1/23/09 2:25:48 PM

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Dow Chemical 4-08.indd 1 1/23/09 11:02:10 AM

3. More of what you want Convey pneumatically to/from
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veying systems transport a
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Flexicon® flexible screw conveyors deliver als over short or long dis-
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ates negative pressure within dust-tight system to collapse
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Circle 04 on p. 62 or go to adlinks.che.com/23011-04
Flexicon 4-07.indd 1 1/23/09 11:16:08 AM

4. Circle 05 on p. 62 or go to adlinks.che.com/23011-05
Solutia 7-08.indd 1 1/23/09 11:22:09 AM

5. February 2009 In This Issue Volume 116, no. 2
Commentary
5 ditor’s Page
E
Is change coming
to the CPI? The
new U.S. Presidential
administration brings
www.che.com with it a renewed
focus on science,
Cover story which has often
34 over Story NANO Know-How This brief
C been the missing link
introduction to nanotechnology provides a between the CPI,
basic understanding to those new to the field policy and public
opinion
NEWS
11
Chementator Construction to begin on a departments
large solar plant in Spain; This centrifugal re- Letters...................... 6
actor/separator speeds up biodiesel produc- Calendar. ............. 8, 9
.
tion; A new syngas catalyst passes pilot tests;
A Ni-based syngas catalyst promises to slash Who’s Who. ........... 32
.
reformer size and costs; A pilot-step closer Reader
to second-generation biofuels; Progress on Service page........... 62
a promising separation technology; Sonicat- Economic
ing slurries speed soil remediation; A sound Indicators. ........ 63, 64
.
equipment services
way to reuse low-temperature waste heat;
Commercialization nears for producing caro- 32 -1 Show Preview Interphex (North
D
tenoids from engineered yeasts; and more American Edition) TThe world's largest advertisers
pharmaceutical conference and exhibi- Product
19 ewsfront Oil From Sand The oil sands in-
N
tion, Interphex, will be held again at the
dustry is growing fast, and so is its impact on Showcase...........54, 55
.
Jacob K. Javits Convention Center in
the environment Classified
New York from March 17 to 19, 2009.
23 ewsfront Taking the Plunge Chemical
N This show preview includes a sampling Advertising........56–60
processors should begin looking into water of the equipment and services that can Advertiser Index...... 61
reuse systems now, as experts suggest tight- be found at the exhibition
ening water supplies will soon be a reality
32I-1 New Products Services coming
across the U.S.
(International Edition) This compact in March
Engineering I/O block module handles up to 16 Look for: Feature Re-
signals; Level control, even for sticky ports on Compressed
27
Solids Processing Selecting a Conveyor
materials; Remove vapors from gases Gas Cylinder Safety;
Characteristics of flexible screw, aero-me-
with this line of disposable filters; This Gas Applications in
chanical, vacuum and pneumatic conveyors
dosing pump features a hydraulically Fine and Specialty
are discussed here
activated diaphragm; Shred big parts Chemistry; Combining
31
Facts At Your Fingertips Pipe Sizing with this compact system; A dew point Rupture Disk Devices
This one-page guide provides the formulas transmitter for when the pressure is on; with Safety Relief
needed to approximate friction factors, dis- A low-cost solution for remote moni- Valves; and Getting
charge, pressure drop, and pipe diameter toring and control; This module lets the Most Out of Your
40 eature Report Part 1 Plate Heat Exchang-
F flowmeters communicate via fieldbus; Rupture Disk; A You
ers: Avoiding Common Misconceptions A This water distribution system is pre- and Your Job article
solid understanding of the critical areas presented validated; and more on Increasing Produc-
here will insure good performance tivity by Using Web
52 ocus Flow Measurement Control
F 2.0 Tools; A Focus
44 eature Report Part 2 Compact Heat Ex-
F This unit offers measurements for low on Milling Grind-
changers: Improving Heat Recovery These flows in the millimeter range; Use this ing; News articles
units offer distinct advantages over shell-and- thickness gauge for ultrasonic clamp-on on Solar Energy; and
tube heat exchangers, as quantified by the ex- flowmeters; Remote mass flowmeter for Wireless Instrumenta-
ample presented here small lines in hazardous areas; A new tion Networking;
48 nvironmental Manager Eye-and-Face
E technology platform for flow computers Facts at Your Finger-
Personal Protective Equipment Protecting is introduced; Measure mass or volu- tips on Membranes;
the eyes and face in the workplace is impera- metric energy flow with this meter; This An Achema Show
tive to preventing the estimated 10–20% of Coriolis mass flowmeter is corrosion-re- Preview; and more
work-related eye injuries that result in tem- sistant; Custom calibrate these variable
porary or permanent vision loss area flowmeters; and more Cover: David Whitcher
Chemical Engineering www.che.com February 2009 3
02_CHE_021509_TOC.indd 3 1/26/09 8:38:53 AM

6. Circle 06 on p. 62 or go to adlinks.che.com/23011-06
swagelok 6-06.indd 1 1/23/09 11:36:49 AM

7. Winner of Eight Jesse H. Neal
Awards for Editorial Excellence
Editor’s Page
Published since 1902
Is change coming to the CPI?
A
An Access Intelligence Publication lthough the inauguration of the U.S.’s 44th President is now fading into
Publisher Art Design
memory, the changes that Barack Obama’s Administration will bring to
Mike O’Rourke DAVID WHITCHER
the chemical process industries (CPI) are only beginning to reveal them-
Publisher Art Director/ selves. One thing is very clear, though: In these tough economic times, some
morourke@che.com Editorial Production Manager
dwhitcher@che.com
very important policy issues are on the agenda with direct implications to our
Editors
Production field. At the top of the list are plant security and energy, both of which are
Rebekkah j. Marshall
Editor in Chief MICHAEL D. KRAUS complicated by a longstanding public-relations challenge.
rmarshall@che.com VP of Production Manufacturing As change in Washington gets off the ground, an additional shift in leader-
mkraus@accessintel.com
Dorothy Lozowski
Steve Olson
ship has already taken root on the other side of the Potomac River. In Septem-
Managing Editor
dlozowski@che.com Director of Production ber of last year Cal Dooley, a 14-year member of the U.S. House of Representa-
Manufacturing
GERALD ONDREY (Frankfurt) solson@accessintel.com
tives, officially took reigns as president and CEO of the American Chemistry
Senior Editor
gondrey@che.com WILLIAM C. GRAHAM Council (ACC; Arlington, Va.; www.americanchemistry.com). With first-hand
kate torzewski
Ad Production Manager appreciation for advocacy in Washington, Dooley is wasting no time reaching
bgraham@che.com
Assistant Editor
Marketing
out to the new legislative and executive branches of government.
ktorzewski@che.com
Holly Rountree
One of the first major steps Dooley took after the November election in-
SUZANNE A. SHELLEY
Contributing Editor Marketing Manager volves a letter and paper detailing ACC’s clean-energy economic-recovery
hrountree@accessintel.com
sshelley@che.com proposals, both of which were sent on December 18, 2008 to congressional
Audience
CORRESPONDENTS Development leadership, committee leaders in both parties and the Obama transition.
Charles ButcheR (U.K.)
Sylvia sierra Dooley writes, “The ACC supports new government investment in clean
cbutcher@che.com
Senior Vice President, energy programs because these programs create jobs, improve the nation’s
Paul S. Grad (Australia) Corporate Audience Development
pgrad@che.com ssierra@accessintel.com energy security, and reduce greenhouse gas emissions. American chemistry
Tetsuo Satoh (Japan) John Rockwell also plays an important role in achieving these goals. Our industry produces
Vice President,
tsatoh@che.com
Audience Development Chemical
materials that make the rest of the economy more energy efficient (for in-
Joy LePree (New Jersey) jrockwell@accessintel.com stance, insulation, light-weight vehicle parts). We also make materials used
jlepree@che.com
Gerald parkinson
Laurie Hofmann in clean energy technologies (for instance, wind turbines, solar panels, lith-
Audience Marketing Director
(California) gparkinson@che.com lhofmann@Accessintel.com ium-ion batteries). At the same time, American chemistry invests in technol-
Editorial Terry Best ogies and services that improve the energy efficiency of our own operations
Advisory Board Audience Development Manager
tbest@accessintel.com
(for instance, high efficiency combined heat and power systems). Given that
John Carson
Jenike Johanson, Inc. George Severine our products are the fundamental building blocks of green technologies and
David Dickey Fulfillment Manager energy efficiency, we believe our workforce is employed in ‘green jobs’. It is
gseverine@accessintel.com
MixTech, Inc.
Christie Lamont
imperative that these domestic jobs be retained and expanded.”
Mukesh Doble List Sales, World Data 561-393-8200 From the Executive Summary of the American Recovery and Reinvest-
IIT Madras, India
Henry Kister
Conferences ment Bill of 2009 that was released by the House of Representatives Ap-
Fluor Corp. Dana D. Carey propriations Committee on January 16th, it appears that lawmakers heard
Director, Global Event Sponsorships
Trevor Kletz dcarey@chemweek.com at least part of ACC’s message. The stimulus includes funding for science
Loughborough University, U.K.
Peck Sim and technology, especially in the areas of renewable, clean energy. ACC’s
Gerhard Kreysa
DECHEMA e.V.
Senior Manager,
Conference Programming
response, conveyed more recent letters to Congress, urges the committee
Ram Ramachandran psim@chemweek.com to bulk up investments in gasification technologies, carbon capture and se-
BOC Beatriz Suarez questration systems, and buildings and industrial efficiency programs. .
Director of Conference Operations
Information
bsuarez@chemweek.com The key undertone to these and other recent policy discussions is simply
services
Robert Paciorek
Corporate science, which has often been the missing link where policy and public opinion
Senior VP Chief Information Officer Steve Barber come together. “We are committed to advancing our public policy priorities on
rpaciorek@accessintel.com VP, Financial Planning Internal Audit
sbarber@accessintel.com
science-based foundation. Our industry’s commitment to solid research and
Charles Sands
Senior Developer Brian Nessen good science has driven us to be among the most innovative sectors in the
Web/business Applications Architect Group Publisher world. Science is the basis for our strong safety, health and environmental
csands@accessintel.com bnessen@accessintel.com
performance, and will continue to be the hallmark pillar of the business of
Headquarters
chemistry,” Dooley tells CE.
110 William Street, 11th Floor, New York, NY 10038, U.S.
Tel: 212-621-4900 Fax: 212-621-4694 ACC has been very supportive of Obama’s key Admin-
European Editorial offices istration appointments, which in themselves indicate an
Zeilweg 44, D-60439 Frankfurt am Main, Germany outstretched arm to science. In a statement released dur-
Tel: 49-69-2547-2073 Fax: 49-69-5700-2484
ing Senate confirmation hearings, Dooley used the word
Circulation Requests:
Tel: 847-564-9290 Fax: 847-564-9453
“exciting” to describe the selection of Nobel-prize winning
Fullfillment Manager; P.O. Box 3588, physicist Dr. Steven Chu, for U.S. Secretary of Energy.
Northbrook, IL 60065-3588 email: clientservices@che.com
So while we cannot fully answer how change is coming
Advertising Requests: see p. 62
to the CPI, there is some solace the premise that science is
For photocopy or reuse requests: 800-772-3350 or info@copyright.com
For reprints: chemicalengineering@theygsgroup.com descending — in force — on Washington. ■
Rebekkah Marshall
Chemical Engineering www.che.com February 2009 5
03_CHE_021509_ED.indd 5 1/27/09 2:40:05 PM

8. Letters
Sharing personal achievement
I read with much surprise and pleasure your December
2008 issue, which covered Chemical Engineering’s 2008
Personal Achievement Awards. The nomination is very
meaningful for me coming from people in my team, and
the selection is truly humbling. However, I wish to say
that the efforts put in to improve the performance and
protect the environment, and the record performances of
the companies come as a result of team work. Most of the
actual modification work has been done by the dedicated
personnel in the two companies, namely See Sen Chemi-
cal Bhd and Malay-Sino Chemical Industries Sdn Bhd.
Both are companies with histories spanning 30 years.
But both companies have been breaking records every
year for the past few years due to the tireless efforts of
their dedicated technical personnel. Most of the improve-
ments are from application of basic good engineering
practice, like going back to basics, while also looking
after the environment. This has really yielded dividends
for the company. I see my selection for the award more as
a recognition of all the effort put in by all the dedicated
personnel in these two companies. There is much more
for us to achieve.
Shyam Lakshmanan
See Sen Chemical Bhd and Malay-Sino Chemical
Industries Sdn Bhd.
ACS Rubber division, call for papers
The Rubber division of the American Chemical Society
(www.rubber.org) is now accepting online abstract submis-
sions for the 176th technical meeting being held during
the Rubber Expo, October 13–15, 2009, Pittsburgh, Pa.
Scheduled symposia include the following:
• Automobile Elastomers and Engineered Products
• Contributed Sessions
• lastomeric Materials: Challenges in Pharmaceutical/
E
Biomedical Applications
• Elastomers for Wire Cable Industry
• Filler Reinforcement of Rubber
• Mixing and Processing
• Natural Rubber and Natural Rubber-based Products
• New Commercial Developments
• Rubber Recycling
• Rubber Science
• Rubber Testing
• Science of Rubber Stabilization Vulcanization
• ynthetic Rubbers and Synthetic Rubber-based Products
S
• Thermoplastic Elastomers
• Tire Technology
Abstract Deadline: April 10, 2009.
Postscripts, corrections
November 2008, Bringing the corrosion resistance of tan-
talum to off-the-shelf stainless-steel parts, p. 16: In the
original version, the company location and Website are
both misspelled. The corrected details are Tantaline (Lyn-
gby, Denmark; www.tantaline.com).
Circle 07 on p. 62 or go to adlinks.che.com/23011-07
6 Chemical Engineering www.che.com February 2009
04_CHE_021509_LET.indd 6 1/23/09 8:57:03 AM

9. Circle 08 on p. 62 or go to adlinks.che.com/23011-08
Honeywell 10-07.indd 1 1/23/09 11:43:01 AM

10. Chemical Engineering half 3 3/8 x 10:Inter labmate half page
Calendar
NORTH AMERICA
Coating 2009 West. The Powder Coating Insti-
THE WORLD FORUM OF THE PROCESS INDUSTRIES
tute (The Woodlands, Tex.). Phone: 832-585-0770; Fax:
832-585-0220; Web: thecoatingshow.com
Las Vegas, Nev. Mar. 2–3
Sustainability in Packaging 2009. IntertechPira Ltd.
(Portland, Maine). Phone: 207-781 9800; Fax: 207-781
2150; Web: sustainability-in-packaging.com
Orlando, Fla. Mar. 2–4
Pittcon 2009. The Pittsburgh Conference on Analytical
Chemistry and Applied Spectroscopy, Inc. (Pittsburgh,
Pa.). Phone: 412-825-3220; Web: pittcon.org
Chicago, Ill. Mar. 8–13
Renewable Energy World Conference Expo.
PennWell (Tulsa, Okla.). Phone: 918-831-9161; Fax:
918-831-9160; Web: renewableenergyworld-events.com
Las Vegas, Nev. Mar. 10–12
Strategize to Optimize — PAS Users Conference
2009. PAS, Inc. (Houston. Tex.). Phone: 281-286-6565;
Be part of the Fax: 281-286-6767; Web: pas.com/usersconference
Houston, Tex. Mar. 9–11
bigger picture... 2009 AATCC International Conference. American
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angle Park, S.C.). Phone: 919-549-8141; Fax: 919-549-8933;
... and see innovations of today Web: aatc.org/ice
for the solutions of tomorrow Myrtle Beach, S.C. Mar. 10–12
Design Manufacturing South. Canon Communica-
The global appeal of ACHEMA gives you a competitive edge by tions (Los Angeles, Calif.). Phone: 310-445-4200; Fax:
allowing you to see the bigger picture. 310-996-9499; Web: canontradeshows.com
ACHEMA attracts engineers, chemists and decision makers from around Charlotte, N.C. Mar. 11–12
the world to a single venue to showcase solutions, share ideas and
interface across technology disciplines. Interphex 2009. Reed Exhibitions (Norwalk, Conn.).
Be better prepared for the challenges to come – Attend ACHEMA. Phone: 203-840-5533; Fax: 203-840-9533;
Web: interphex.com
� CHEMICAL ENGINEERING � SAFETY New York, N.Y. Mar. 17–19
� BIOTECHNOLOGY � ADVANCED MATERIALS
� ANALYTICAL TECHNIQUES � ENVIRONMENTAL PROTECTION
� FLUID HANDLING � RESEARCH 2009 National Petrochemical Refiners Associa-
� PROCESS AUTOMATION � SPECIAL SHOW:
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PROCESSES San Antonio, Tex. Mar. 22–24
4,000 EXHIBITORS � 180,000 ATTENDEES � 30,000 EXECUTIVES ACS Spring 2009 National Meeting Exhibition.
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Salt Lake City, Utah Mar. 22–26
FIATECH 2009 Technology Conference Show-
case. FIATECH (Austin, Tex.). Phone: 512-232-9600; Fax:
www.achema.de 512-232-9677; Web: fiatech.org
www.dechema.de Las Vegas, Nev. Apr. 6–8
2009 Water Security Congress. American Water
Works Association (Denver. Colo.). Phone: 303-794-7711;
Circle 09 on p. 62 or go to adlinks.che.com/23011-09
8 Chemical Engineering www.che.com february 2009
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national Society of Automation (Research Triangle Park. metals, food, fertilizer, plastic,
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9th European Gasification Conference. Institute 4525 Weaver Pkwy, Warrenville, IL 60555
of Chemical Engineers (Rugby, U.K.). Phone: +44 01788 Toll free: 877.661.5509
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LogiChem Europe 2009. Worldwide Business Research
(London, U.K.). Phone: + 44 (0) 20 7368 9465; Fax: + 44 (0)
20 7368 9401; Web: logichemeurope.com
Düsseldorf, Germany Mar. 31–Apr. 3
MAXIMIZE YOUR MEMBRANE’S
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Manama, Bahrain Mar. 15–18
Powder World 2009. China Powder Technology As- 407-322-2500
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Beijing, China Apr. 1–3 ■ NanoCeram® is a Registered Trademark of the Argonide Corporation 2005. All right reserved.
HyFlow™ is a Trademark of the Argonide Corporation 2007. All rights reserved.
Kate Torzewski
Circle 11 on p. 62 or go to adlinks.che.com/23011-11
Chemical Engineering www.che.com february 2009 9
Argonide_ChemicalEngineering_rev1c.indd 1 1/14/09 9:14:30 PM
05_CHE_021509_CAL.indd 9 1/22/09 11:14:12 AM

12. 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,
low-profile design fits tight spaces. There’s no better way to stop
temperature fluctuations than the Fisher GX 3-way valve. Learn more
at www.Fisher.com/gxCE or contact an Emerson sales office.
Circle 12 on p. 62 or go to adlinks.che.com/23011-12
The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2008 Fisher Controls International LLC MU35-CD197
Emerson Valve 1-09.indd 1 1/23/09 11:47:07 AM

13. Edited by Gerald Ondrey February 2009
Construction to begin
on a large solar plant in Spain
T hanks to a �171-million financing deal, con-
struction can begin on what is claimed to
be the world’s first utility-grade solar power
plant with central tower and salt receiver
technology. When the so-called Gemasolar
plant — located in Fuentes de Andalucia,
Spain — is operational in 2011, it will produce
17 MWe of power, reducing CO2 emissions by
more than 50,000 metric tons per year (m.t./
yr) that would be released by a conventional
power plant of the same capacity.
The Gemasolar plant (diagram) will con-
sist of 2,500 heliostats, which will track
the sun and focus sunlight to a receiver at
the top of a tower. There, 95% of the radia-
tion is absorbed and converted to thermal
energy, which is used to heat molten salts Torresol Energy
(potassium and sodium nitrates). The hot
salts descend to a tank where it is stored com), a strategic alliance between Sener
at about 500°C. In a second loop, the mol- Ingeniería y Sistemas (Madrid; www.sener. A new bioplastic
ten salt passes through a heat exchanger. es) and Masdar (www.masdaruae.com), Abu Up to now, the main plastic
and the energy is used to produce steam, Dhabi’s renewable-energy initiative. The en- produced from renewable re-
which drives a turbine for generating elec- gineering, procurement, construction contract sources has been polylactic
tricity. The molten salt’s storage capacity is has been awarded to a consortium, including acid (PLA), which is derived
designed to enable power generation for 15 Sener and AMSA, an ACS Cobra (Madrid; from corn starch. However, be-
hours without sunlight. www.grupocobra.com) subsidiary. Sener will cause PLA does not have the
Gemasolar is a project of Torresol Energy provide the technology, the detailed design same level of performance as
S.A. (Madrid, Spain; www.torresolenergy. and commissioning of the plant. petroleum-derived plastics, PLA
has not been actively adopted
by certain industries, accord-
This centrifugal reactor/separator ing to Teijin Ltd. (Tokyo, Japan;
www.teijin.co.jp/english). The
speeds up biodiesel production company plans to change this
situation with the commercial
A continuous process for producing biod-
iesel that has a residence time of about
one minute, versus several hours for a con-
tor and rapidly mixed at 3,600 rpm. The re-
action time is approximately 1 min, at which
point the lighter methyl esters (biodiesel)
launch, later this year, of a
new heat-resistant bioplastic,
dubbed Biofront. Biofront is a
ventional batch process, has been developed and heavier glycerol are separated by the stereocomplex PLA made with
at Oak Ridge National Laboratory (ORNL; centrifugal action. The biodiesel yield for a high-purity L- and D-lactate,
which has a melting point of
Oak Ridge, Tenn.; www.ornl.gov). The pro- 5:1 oil-to-methoxide ratio is about 95%, with
210°C — significantly higher
cess uses a centrifuge for simultaneous less than 1% carryover of either phase into
than the 170°C for conventional
synthesis of biodiesel and separation of the the other, he says. Current work is focused PLAs — and “rivals” that of
biodiesel from the glycerol byproduct. ORNL on increasing the yield. polybutylene terephthalate
has done laboratory tests and is collaborat- Initially, the researchers were working (PBT), says the firm.
ing with biodiesel producer Nu-Energie with a conventional centrifugal contactor, Teijin is currently operating a
(Surgoinsville, Tenn.) to do a pilot test at the but the residence time was too short at the 200-ton/yr Biofront pilot plant. It
Nu-Energie facilities later this year. 3,600-rpm speed required for thorough mix- recently acquired a 1,000 ton/yr
The key to the process is a Couette reac- ing, says Tsouris. “The Couette unit provides PLA demonstration plant from
tor/separator, a type of centrifuge that until a residence time of about one minute,” he Toyoto Motor Corp. (Tokyo); this
new facility is expected to pro-
now has been used only in the laboratory, says. He adds that the reactor/separator can
duce Biofront later this summer.
says Costa Tsouris, a research engineer with be scaled up to production size and promises
A 10,000-ton/yr Biofront plant is
ORNL. Food-grade soy oil and sodium meth- to reduce the size of the production equip- also expected to be completed
oxide (a mixture of methanol and sodium ment to well below 10% of that used in a in 2010.
hydroxide) are fed separately into the reac- conventional batch operation.
Note: For more information, circle the 3-digit number
on p. 62, or use the website designation. Chemical Engineering www.che.com February 2009 11
06_CHE_021509_CHM.indd 11 1/26/09 8:46:39 AM

14. C hementato R Final specs for SIF
Last month, the Fieldbus
Foundation (Austin, Tex.;
www.fieldbus.org) released
the latest device-development
A new syngas catalyst passes pilot tests . . . solutions for its Foundation
for Safety Instrumented Func-
M itsunori Shimura and colleagues at conditions of 900°C (outlet temperature), tions (SIF) technology, which
the RD Center of Chiyoda Corp. (Yo- 1.9 MPa (gauge) and a molar feed ratio of includes the Foundation for
SIF final Technical Specifica-
kohama, Japan; www.chiyoda.co.jp) have CH4:CO2:H2O = 1.0:0.4:1.15, the new cata-
tion package, SIF Interop-
developed a new catalyst for producing a lyst produced a syngas with H2-to-CO mole
erability Test Kit (ITK) and
synthesis gas (syngas; hydrogen and carbon ratio of 2.0, making it especially suitable updated DD (Device Descrip-
monoxide) from steam reforming of meth- for gas-to-liquids (GTL) applications, or for tion) Library with SIF function
ane. The catalyst consists of precious met- the production of oxo-alcohols (such as n- blocks. The new technical
als selectively loaded on the surface of the butanol) and acetic acid, says the company. specification defines analog
firm’s commercial, egg-shell-shaped sup- In laboratory trials, the catalyst has also input (AI) blocks for fieldbus
port, which results in an effective utilization shown 1,000-h of operation, without deacti- transmitters and other SIF
of the costly metals. vation, for producing syngas with H2-to-CO devices. Future updates to the
The catalyst has been demonstrated in ratios of 1.0. specification will include digi-
tal output (DO) blocks.
a pilot reformer (single, 12-m long tube The catalyst and associated syngas-pro-
with 110-mm dia.), which showed stable, duction process are being developed for a
on-stream operation for 7,000 h, with mini- national GTL project coordinated by JOG- Drought-tolerant corn
mal carbon formation (less than 0.1 wt.%) MEC (Japan Oil, Gas and Metals National First results have been
on the catalyst. With a feed of natural Corp.). A 500-bbl/d GTL plant is under con- achieved from a plant biotech
gas (85 vol.% CH4), and typical operating struction with startup later this year. collaboration between BASF
Plant Science (Limburgerhof,
Germany; www.basf.com/plant-
. . . and a Ni-based syngas catalyst science) and Monsanto Co. (St.
Louis, Mo.; www.monsanto.
promises to slash reformer size and costs com) for a drought-tolerant
corn. The product has moved
K eiichi Tomishige, an associate profes-
sor at University of Tsukuba (www.ims.
tsukuba.ac.jp), has developed a new high-
suppression of hot spots and carbon forma-
tion. The catalyst is also less prone to deac-
tivation by oxidation of Ni, he says.
into the final phase prior to an
anticipated market launch early
next decade, and Monsanto
performance catalyst for the highly efficient Because of the enhanced reactivity, Tom- has submitted the product to
production of syngas, with support from the ishige estimates that reformers operating the U.S. Food and Drug Admin.
(FDA; Washington, D.C.) for
New Energy and Industrial Technology De- with the new catalyst can be one-fourth
regulatory clearance.
velopment Organization (Kawasaki, both the size of a conventional reformer with the
Drought-tolerant corn is de-
Japan). The nickel-based catalyst is selec- same production capacity. And the cost of signed to provide farmers with
tively impregnated with small amounts of the catalyst is expected to be significantly yield stability during periods
precious metals (Pt, Pd and Rh) on the sur- lower due to the use of predominantly nickel when water supply is scarce by
face. By performing the impregnation se- with reduced amounts of precious metals. mitigating the effects of water
quentially, rather than by conventional co- The researchers are planning to scale up stress within a corn plant.
impregnation, Tomishige is able to control their work and apply the catalyst technol- Field trials for the new corn
the structure of bi-metallic (Ni and precious ogy to the oxidative-reforming of other hy- met or exceeded the 6–10%
metal) particles on the surface. This leads to drocarbon feeds, such as city gas, gasoline, target yield enhancement over
the average yield of 70–130
active sites that accelerate both exothermic methanol and kerosene, with the aim to pro-
bushels per acre in some key
and endothermic reactions, resulting in the duce H2 for fuel cells.
drought-prone areas of the
U.S., says BASF.
A pilot-step closer to second-generation biofuels
L urgi GmbH (Frankfurt, Germany;
www.lurgi.com) is building a pilot
plant to demonstrate the viability of its
500°C) converts biomass into a trans-
portable, liquid intermediate product
(bioliqSynCrude) whose energy den-
the basis of Lurgi’s proprietary Multi-
Purpose Gasifier (MPG) — is equipped
with a castable, lined cooling screen
three-stage bioliq process for produc- sity is 13–15 times higher than that that is cooled with pressurized water,
ing liquid fuels from biomass. The pilot of straw. The bioliqSynCrude is then and whose internal surface is pro-
plant — an entrained-flow gasifier for preheated to around 80°C, pressurized tected from corrosion and erosion by
the production of synthesis gas — will be and fed to the bioliq gasifier, where it is a layer of slag. Crude syngas and slag
located at the Karlsruhe Research Cen- converted (at above 1,400°C) into syn- are drawn off via a quench at the bot-
ter (FZK; Germany; www.fzk.de), and is gas. In the final step, the syngas (pro- tom of the reactor.
part of a joint project with the Karlsruhe duced at high pressure) is purified and The fast pyrolysis pilot plant — the
Institute of Technology (KIT). fed to a synthesis unit for conversion first step of bioliq — was commissioned
In the first step of the bioliq process, to fuels. last year at KIT; startup for the bioliq
a fast pyrolysis process (operating at The bioliq gasifier — developed on gasifier is planned for the Fall of 2011.
12 Chemical Engineering www.che.com February 2009
06_CHE_021509_CHM.indd 12 1/26/09 8:47:48 AM

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Circle 13 on p. 62 or go to adlinks.che.com/23011-13
HAP_CE 7.875x10.75_tubular drag.indd 1 12/10/08 1:44:37 PM
Hapman 2-09.indd 1 1/23/09 12:00:44 PM

16. C hementato R
Transport
through Transport along
the the sweep side
porous
layer
Progress on a promising Transport along
the feed side
separation technology
F or separating two components with simi-
lar volatilities, extractive distillation
is typically used, whereby a high-boiling,
TU Delft
non-volatile solvent is added to “break the
azeotrope” — a process that is both energy more friction with the sweep gas in the po-
intensive and often involves the use of haz- rous layer, lighter components diffuse at a Furanics
ardous solvents. In an effort to reduce the higher rate into the shell side. As a result, Royal Cosun (Breda; www.
energy requirements and avoid the use of the vapor emerging from the tube side is cosun.com) and Avantium
hazardous solvents used in extractive dis- enriched with the heavy component. Enrich- (Amsterdam, both Nether-
tillation, an alternative separation tech- ments of 65–70% have been achieved in a lands; www.avantium.com)
nology, called frictional diffusion (FricDiff) single-tube FricDiff unit for isopropanol- have started a two-year col-
is being developed by a consortium of aca- water and helium-argon mixtures; however, laboration to develop a specific
process for the production of a
demic (TU Delft and TU Eindhoven) and in- “the balance between enrichment and recov-
new generation of bioplastics
dustrial partners (Akzo Nobel, Shell Global ery is a major challenge we are investigat-
and biofuels — tradenamed
Solutions, Bodec, FIB Industriële Bedrijven ing,” says Aylin Selvi, a doctoral student at Furanics — from selected
BV and Purac), with financial support from the Process Energy Laboratory, Delft Uni- organic waste streams. For
Senter-Novem (all Netherlands). versity of Technology (www.tudelft.nl). Com- a number of years, Avantium
FricDiff is based on the difference in dif- puter simulations set up by TU Eindhoven has been developing Furanics,
fusion rate of two components when diffus- indicate that 90% enrichments are possible which can be produced from
ing through a third component (sweep gas). when operating with an overpressure of sugars and other carbohy-
In a FricDiff unit, the vapor mixture flows sweep gas, she says. drates from biomass. These
through the tube side of a porous, stainless- Last month, the engineering work was bioplastics can be produced
cheaper than petroleum-based
steel cylinder, while the sweep gas flows completed for a scaled-up test unit, which in-
materials, says Avantium.
counter currently on the shell side. Because corporates seven FricDiff tubes. This test unit
heavier components in the feed experience will be operated at TU Delft starting April.
Single-site catalyst
Last month, LyondellBasell
Industries (Rotterdam, Nether-
Sonicating slurries speeds soil remediation lands; www.lyondellBasell.com)
launched a new Avant M single-
U ltrasound has been applied, with limited
success, for the remediation of contami-
nated soil. Up to now, the approach has been
cally about 50 µm in dia. at the moment of
collapse — are so high that any decompo-
sition products from the pyrolysis reaction
site catalyst system, which
extends the performance capa-
bilities of its Metocene polypro-
to first extract the contaminant from the soil are very rapidly quenched, eliminating the pylene (PP) production technol-
into a liquid, which is then passed through possibility of recombination reactions. The ogy. The new catalyst extends
a sono-reactor where the contaminants are team has confirmed that radical formation, the range of homopolymer,
destroyed by high temperatures and pres- which plays an important role in conven- random and impact copolymer
sures (more than 5,000K and 1,000 atm) tional sonochemistry, does not occur in slur- grades by offering performance
generated by cavitating bubbles. A new pro- ries, and that pyrolysis is the dominant pro- from very low to very high melt
flowrates, while maintaining
cess developed by a team from CSIRO Ma- cess, says Collings.
“outstanding” levels of homo-
terials Science and Engineering (Lindfield, The team has conducted a series of stud-
geneity, transparency and other
Australia; www.csiro.au), in which flowing ies with samples over a wide range of per- features of single-site catalysts,
slurries are passed through a sono-reactor, sistent organic pollutants (POPs) adsorbed says the firm.
has been shown to be 100-times faster than on glass beads, and has progressed to pilot-
liquid-based methods. plant scale. Sonication at 20 kHz with a PA-11 for gas pipelines
The increased speed is believed to be the power of 150 W leads to a 90% reduction
The U.S. Dept. of Transportation
result of bubbles that nucleate and grow on of a polychlorobiphenyl after 1.5 min, and
Pipeline and Hazardous Ma-
the surface of the slurry particles. Instead 99% reduction after 7 min (97% reduction terials Safety Admin. (PHMSA;
of imploding symmetrically, as in liquids, of hexachlorobenzene after 10 min), with Washington, D.C.; http://phmsa.
these bubbles collapse toward the particle, no traces of breakdown products. Similar dot.gov) published a final rule —
forming a high-speed jet that impacts on the results are obtained for clays contaminated effective January 23, 2009 — to
solid surface, explains CSIRO researcher with herbicides and total petroleum hydro- amend 49CFR Part 192 to in-
Anthony Collings. Any substance adsorbed carbons. The pilot-plant studies are aimed at crease the maximum allowable
to the solid surface bears the brunt of this optimizing the process and confirming the operating pressure (MAOP)
implosive energy, and the temperature rise low operating expenses suggested by small- for Polyamide-11 (PA-11) pipes
from 100 psig to 200 psig in
is sufficient to pyrolyze the pollutant. The scale experiments and the practicality of a
(Continues on p. 16)
heat transfer rates in these bubbles — typi- transportable treatment facility.
14 Chemical Engineering www.che.com February 2009
06_CHE_021509_CHM.indd 14 1/26/09 8:50:52 AM

17. Circle 14 on p. 62 or go to adlinks.che.com/23011-14
A Box 4 U 1-09.indd 1 1/23/09 12:03:23 PM

18. C hementato R
A sound way to reuse
low-temperature waste heat
I n a so-called thermoacoustic en-
gine, researchers from the Energy
Research Center of the Netherlands
(ECN; Petten, Netherlands; www.
ecn.nl) have achieved a record ef-
ficiency in the conversion of heat to
sound, improving the existing record
of 41% to 48% of the maximum pos-
sible efficiency (Carnot efficiency).
The engine is being developed as a
way to utilize the huge quantities
of waste heat, which normally can-
not be reused because the tempera-
ture level is too low and is thus released torus configuration. In operation (sche-
to the environment. ECN is working with matic, left), the thermoacoustic engine con-
two equipment manufacturers — Bron- verts thermal energy into acoustic energy.
swerk Heat Transfer B.V. (Nijkerk; www. This acoustic energy is then used in a heat
bronswerk.nl) and Dahlman (Maassluis, pump to upgrade waste heat into medium- ECN
both Netherlands; www.dahlman.nl) — to pressure steam, for example.
develop a system that uses a thermoacous- The prototype engine operating at ECN
tic heat pump driven by a thermoacoustic has achieved the record efficiency when
(Continued from p. 14)
engine to upgrade waste heat. driven by heat at high (500–600°C) tem-
The thermoacoustic engine is composed peratures. The next step is to extrapolate certain pipelines. The rule also
of three main parts (diagram, right): a ther- this performance to engines that operate at includes an increase in the
modymamic part, consisting of a regenera- much lower (100–150°C) temperatures, says design factor from 0.32 to 0.40,
tor, two heat exchangers and a thermal buf- project leader Simon Spoelstra. An inte- which applies to PA-11 pipe
fer tube; an acoustic network, consisting of grated laboratory system (engine plus heat with standard dimensional ratio
an acoustic compliance and an inertance; pump) that delivers the required perfor- (SDR) in diameters 4 in. and
and a resonator. The thermodynamic part mance under relevant industrial conditions smaller. Service tubing sizes
and the acoustic network are placed in a is planned for operation in 2010. may have lower SDRs.
The new rule gives opera-
tors of natural gas pipelines
the option to use PA-11 pipe
Commercialization nears for producing in certain pipeline systems.
Arkema Inc. (Philadelphia,
cartenoids from engineered yeasts Pa.; www.arkema-inc.com),
which petitioned the rule
I n late 2009, Microbia PE, Inc. (Lexington,
Mass.; www.microbia-pe.com) will begin
commercialization of its initial carotenoid
chemical-synthesis manufacturers today.
Furthermore, “for some of the more com-
plex carotenoids with greater chirality,” he
change back in October
2004 following extentensive
field tests of its Rilsan PA11
products. Microbia plans to produce b-caro- says, “we believe our costs will be signifi- pipes, says the amended
rule will enable the oil and
tene, astaxanthin, zeaxanthin, cathaxanthin cantly lower.”
gas industry to “fully realize
and lutein — all five carotenoid products Microbia’s fermentation process is carried the cost-saving and ease of
that currently have significant commercial out with the yeast Yarrowia lipolytica. Un- installation benefits of Rilsan
value. These carotenoids have primary ap- like most fermentation processes for carote- P11.” For the same cost ben-
plications as food ingredients, dietary sup- noid manufacture, this yeast achieves very efits, Rilsan PA11 pipes offer
plements and animal feed ingredients. high yields of the carotenoids, with a unique all the advantages of conven-
Though chemically identical to carote- strain engineered for the production of each tional polyethylene pipes at
noids that are currently on the market, this carotenoid. A series of optimized enzymatic pressures normally requiring
firm’s products will be made by fermenta- steps facilitates efficient biosynthesis. steel, including coiled pipe
tion of natural raw materials, such as sugar In addition to the technology inherent in that can be plowed or planted,
joined by butt fusion and elec-
and vegetable oils, rather than by conver- its carotenoid commercial interests, Micro-
trofusion, and squeezed off
sion from petrochemical-based materials. bia is also collaborating with partners, such like conventional pipe, says
Microbia CEO Richard Bailey explains as Tate Lyle Plc (London, U.K.), to develop the firm. ❏
that projected product costs are at least bioprocesses for manufacturing larger-vol-
on par with products from the lowest-cost, ume, commodity chemicals. ■
16 Chemical Engineering www.che.com February 2009
06_CHE_021509_CHM.indd 16 1/26/09 8:53:20 AM

19. Circle 15 on p. 62 or go to adlinks.che.com/23011-15
Badger Meter 2-09.indd 1 1/23/09 12:06:44 PM

20. Circle 16 on p. 62 or go to
adlinks.che.com/23011-16
Flexitallic 2-09.indd 1 1/23/09 12:10:52 PM