Chemical industry, 1, 21—25 components

The DIPPR is a research organization sponsored by the AlChE (American Institute of Chemical Engineers). Its objective is to develop a thermophysical data bank for the components most frequently encountered in the chemical industry. 

The term feedstock in this article refers not only to coal, but also to products and coproducts of coal conversion processes used to meet the raw material needs of the chemical industry. This definition distinguishes between use of coal-derived products for fuels and for chemicals, but this distinction is somewhat arbitrary because the products involved in fuel and chemical appHcations are often identical or related by simple transformations. For example, methanol has been widely promoted and used as a component of motor fuel, but it is also used heavily in the chemical industry. Frequendy, some or all of the chemical products of a coal conversion process are not isolated but used as process fuel. This practice is common in the many coke plants that are now burning coal tar and naphtha in the ovens. 

Parts made from fluoroelastomers ate used ia appHcations that justify their high cost, usually where the maintenance and replacement costs are high enough to offset the initial cost of the part. These include automotive appHcations such as valve stem seals, fuel injector components, radiator, crankcase and transmission seals, and carburetor needle tips. Numerous seals and gaskets in the marine, oilfield, and chemical processing industries employ fluoroelastomers. In addition, many hoses in the automotive and chemical industry are made entirely of fluoroelastomer compounds or have a veneer of the fluoroelastomer as a barrier exposed to the harsh environment. Seals and gaskets in military appHcations and the binder for flares and missile appHcations ate made with fluoroelastomers. 

QRA practitioners can use to satisfy some QRA objectives. Also, the American Institute of Chemical Engineers (AIChE) has sponsored a project to expand and improve the quality of component failure data for chemical industry use. And many process facilities have considerable equipment operating experience in maintenance files, operating logs, and the minds of operators and maintenance personnel. These data can be collected and combined with industrywide data to help achieve reasonable QRA objectives. However, care must be exercised to select data most representative of your specific system from the wide range available from various sources. Even data from your own plant may have to be modified (sometimes by a factor of 10 or more) to reflect your plant s current operating environment and maintenance practices. 

The use of electrochemical protection in the chemical industry started about 20 years ago, which is somewhat recent, compared with its use for buried pipelines 40 years ago. Adoption was slow because the internal protection has to be tailored to the individual plant, which is not the case with the external protection of buried objects. Interest in internal protection came from the increasing need for greater safety for operating plants, increased demands for corrosion resistance, and larger plant components. While questions of its economy cannot generally be answered (see Section 22.6), the costs of electrochemical protection are generally less than the cost of equivalent and reliable coatings or corrosion-resistant materials. 

Batch crystallizers are widely used in the chemical and allied industries, solar saltpans of ancient China being perhaps the earliest recorded examples. Nowadays, they still comprise relatively simple vessels, but are usually (though not always) provided with some means of agitation and often have artificial aids to heat exchange or evaporation. Batch crystallizers are generally quite labour intensive so are preferred for production rates of up to say 10 000 tonnes per year, above which continuous operation often becomes more favourable. Nevertheless, batch crystallizers are very commonly the vessel of choice or availability in such duties as the manufacture of fine chemicals, pharmaceutical components and speciality products. 

To get the best estimate, each job should be broken down into its components and separate indices used for labour and materials. It is often more convenient to use the composite indices published for various industries in the trade journals. These produce a weighted average index combining the various components in proportions considered typical for the particular industry. Such an index for the chemical industry in the United Kingdom is published in the journal Process Engineering, Anon. (2004). The composition of this index is ... 

The activation of methane by microwaves has long been a goal of scientists in attempts to convert this natural gas component into higher hydrocarbons valuable in petrochemistry and the chemical industry. Two pathways are being extensively investigated by research groups all over the world ... 

Two common examples of the three components of the fire triangle are wood, air, and a match and gasoline, air, and a spark. However, other, less obvious combinations of chemicals can lead to fires and explosions. Various fuels, oxidizers, and ignition sources common in the chemical industry are... 

An important number of these substances have an industrial origin. Some of them, like the pesticides, arrive intentionally in the environment and their use and release should be theoretically controlled. However, many of them have not been purposely produced as bioactive substances but more as components or additives of certain materials. Their significant growth in the chemical industry has not only been produced as a consequence of the discovery of new active principles in the pharmaceutical or pesticide area, but also because of the expansion of new technologies (electronics, containers, textiles, plastics, resins, foams, etc.), that require the development of new materials and substances with particular features. Most of these substances enter or are discharged to water and air sources without regulated controls. Wastewater treatment plants (WWTPs) are often not yet adapted to completely remove them, and therefore these new compounds can be found to some extent in wastewater effluents as well as in soil and sludge. 

The formulation of objective functions is one of the crucial steps in the application of optimization to a practical problem. As discussed in Chapter 1, you must be able to translate a verbal statement or concept of the desired objective into mathematical terms. In the chemical industries, the objective function often is expressed in units of currency (e.g., U.S. dollars) because the goal of the enterprise is to minimize costs or maximize profits subject to a variety of constraints. In other cases the problem to be solved is the maximization of the yield of a component in a reactor, or minimization of the use of utilities in a heat exchanger network, or minimization of the volume of a packed column, or minimizing the differences between a model and some data, and so on. Keep in mind that when formulating the mathematical statement of the objective, functions that are more complex or more nonlinear are more difficult to solve in optimization. Fortunately, modem optimization software has improved to the point that problems involving many highly nonlinear functions can be solved. 

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