The Chemical Processing Distilled podcast extracts essential elements to serve engineers designing and operating plants in the chemical industry.
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Operator Safety: Winter Is Coming Be Prepared
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As winter approaches, you should assess how well your plant is protected from problems that frigid conditions can pose. In this episode, Managing Editor Amanda Joshi reads a column from Dirk Willard. If you don't have a mother or spouse nagging you to wear a coat, give this a listen. And don't forget to take out the trash! Original column: Safety: …
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Next Generation of Chemical Operators Need Different Training
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Operator roles have expanded beyond valve-turning. Future operators will need broader understanding of chemistry, equipment and instrumentation to effectively troubleshoot and communicate issues. In this podcast we discuss the changing landscape of operator training. Three key factors are driving change: a new generation of workers comfortable with…
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Trending News: Ignoring safety recommendations, Hurricane Beryl fallout and ditching the Chevron Deference
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Here is a look at the three top trending stories as reported on ChemicalProcessing.com. Explosion at Honeywell Plant Occurred Two Years After Replacement Recommendation, CSB Reports --Management approved the project but did not purchase or install a replacement shell before the Jan. 23, 2023, explosion. Dow Reports Power Outage at Freeport Operatio…
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In Case You Missed It brings the written word to life. In today’s episode, Editor-in-Chief Traci Purdum will be reading an article from Tom Blackwood, Chemical Processing’s Solids Advice columnist. This article “Combat Fine Particle Challenges -- What makes them good is also why they’re bad” was published to ChemicalProcessing.com July 22, 2024. He…
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Readers ask questions about their motors and our expert responds. Proper troubleshooting is important. Here are a few questions that were posed to our motors expert, Tom Bishop, over the years. Bishop is a senior technical support specialist with the Electrical Apparatus Service Association (EASA). He joined the EASA staff in 2002 with over 30 year…
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Fixing Fixation Problems in the Chemical Industry
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This cognitive bias has operators clinging to beliefs despite contrary evidence. In this episode, we discuss fixation, also known as confirmation bias or tunnel vision. It’s a cognitive bias in which people cling to beliefs despite contrary evidence. Dave Strobhar and Traci Purdum discuss how fixation can be problematic in industrial settings, citi…
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Focus on clarity in an engineering report. While such reports fall into several types — cost estimates, engineering calculations, proposals and studies (e.g., related to laboratory work or calibration, failures and inspections, or optimization) — all benefit from a clear discussion and conclusion. Sometimes this requires flexibility to stray from a…
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June Roundup: Great Molasses Flood, Barbie Impacts Chemical Industry, EPA’s Tight Grip On Toxic Chemicals
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Distilled News examines the top three stories trending on chemicalprocessing.com. Hosted by Jonathan Katz, executive editor of Chemical Processing. Safety Lessons from the Great Molasses Flood of 1919 Regulatory Burdens, Barbie and Taylor Swift Impact the Chemical Industry EPA Tightens Grip on Toxic Chemicals, Industry Feels the Heat…
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Hackers Target Manufacturing For Intellectual Property, Money -- Guest Episode
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Hackers are targeting manufacturing to leverage intellectual property for big money. In a recent episode of Automation Chat, from Chemical Processing's sister publication The Journal from Rockwell Automation, Theresa Houck, executive editor and host of Automation Chat, digs deep into a study regarding advancing digital transformation in a time of u…
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Operator training hasn’t really changed in the past 50 years, relying heavily on on-the-job training with experienced operators as instructors. However, these operators often lack formal training in teaching methods and techniques. In this episode, we highlight the potential benefits of simulation-based training and the use of dedicated trainers, a…
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Management: Keep Cool When Thawing Projects
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In this ICYMI episode Amanda Joshi, managing editor, reads a column from Dirk Willard on project management. Filed and forgotten, that’s the fate of too many proposals I’ve had to work on. Usually, they relate to somebody’s pet project, an itch that production wanted to scratch, or a worthwhile concept that proved uneconomic. I’m kept busy for a we…
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Drawbacks of Single-Use Tech; Digitalization for Greener Good; ACC’s First-Ever Sustainability Report
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In this episode, Jonathan Katz, executive editor of Chemical Processing, talks about the top stories in May 2024. We learn that you can’t fight climate change without chemistry, the rise of biological drugs is driving explosive growth in the single-use technologies and In an era where decarbonization and digitalization are increasingly recognized a…
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8 Accidental Discoveries that Advanced the Chemical Industry
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Bob Ross isn’t the only one to have happy accidents. Accidental discoveries have significantly advanced the chemical industry and led to numerous groundbreaking innovations. These serendipitous findings have often paved the way for the development of new materials, processes and applications that have had a profound impact on various sectors.…
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A Better Way To Zero In On Chemical Ingredients
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Time is critical when tracking down hazardous substances. Whether it’s trying to mitigate safety incidents before they happen, comply with applicable safety and environmental regulations, or gather all the pertinent information during an emergency involving a chemical spill, fire or natural disaster, having an efficient way to trace every ingredien…
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Beware of Blending Myths in Chemical Processing
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The problem with particulate solids is they segregate every time we turn around. Why? Because they are a two-phase material and only about half is the solid we’re interested in. As a troubleshooter at corporate engineering, the most common call I got from plants was about blenders that didn’t blend. The problems arose because people believed some m…
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Chemical Industry news for the week of April 29, 2024
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In the news this week: The U.S. EPA finalizes methylene chloride ban; Plastics Treaty negotiations wrap up in Ottawa; and Dow and BASF report lower Q1 sales.Por chemicalprocessing
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How Storytelling Improves Operator Performance
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In this episode, we explore the importance of storytelling in the chemical industry. From knowledge capture and transfer to making technical information understandable and engaging, storytelling aids in retaining tacit knowledge and contextual understanding and enhances employee engagement.Por chemicalprocessing
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Solutions Spotlight: How Smarter Vacuum Pumps Drive Sustainability in Chemical Plants
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In the chemical industry, digitalization and emissions monitoring are pressing operational challenges. While exploring the technological innovations behind these trends, attention often shifts to advanced software and precision sensing technologies. But the critical components that ensure the smooth operation of a process plant can be overlooked. C…
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Chemical Processing News for the Week of April 5
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This week’s news roundup examines the collapse of the Francis Scott Key Bridge in Baltimore and how it could impact the chemical supply chain. We also learn that several U.S. oil companies are following in the footsteps of Dow by announcing their plans to utilize small nuclear reactors to meet their electricity requirements. And finally, in the Did…
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ICYMI Project Management: Workflows Matter
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In Case You Missed It brings the written word to life. In today’s episode, I will be reading an article from Andrew Sloley, Chemical Processing’s Plant InSites columnist. This column “Project Management: Workflows Matter” was published on our website on March 30, 2022. Written by: Andrew Sloley, Plant Insites columnist Read by: Traci Purdum, editor…
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Chemical Processing News Week of March 18, 2024
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Executive Editor Jonathan Katz catches us up on what's new in the chemical industry.Por chemicalprocessing
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Operator Training: Remove Team Performance Barriers
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Research on team performance barriers finds that fatigue, workload, competing priorities, conflicting information, and lack of technical expertise are significant hurdles. Psychological safety is crucial for effective team environments, allowing individuals to speak up and admit uncertainty without fear of reprisal. Tools such as self-assessment gu…
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Solutions Spotlight: Coriolis Meters Eliminate Assumptions
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The combination of high accuracy, versatility, direct mass measurement and minimal maintenance requirements make Coriolis meters suitable for various industrial applications. Unlike volumetric flow meters, Coriolis meters directly measure mass flow, making them less susceptible to variations in temperature, pressure and fluid density. To learn more…
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Chemical Processing News for week of March 3, 2024
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This news roundup ponders an elevator to space and questions Chemours ethics.Por chemicalprocessing
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Distilled Chemical News Roundup February 2024
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Exxon looks to balance fossil fuels with sustainability, Didion execs sentenced and yellow snow for battery recycling. This news roundup covers the chemical industry in February 2024.Por chemicalprocessing
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Manage Upsets to Safely Bring the Plant to a Stable Condition
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Upsets are going to happen, so why not plan for it? Learn how. In this episode of Distilled, we discuss managing upsets and distinguishing between shutdown-related and non-shutdown upsets. Dave points out a lot has changed over the years. Indeed, the preference is shutting down during upsets and advancements like safety instrumented systems aid in …
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In today’s episode, Traci Purdum will be reading a column from contributing editor Dirk Willard. This column “Properly Vet Contractors” was published to chemicalprocessing.com October 19, 2021. Engineers once flew around the country to check out contractors’ facilities before signing deals. Nowadays, many bosses instead heavily rely on the Internet…
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Chemical Industry News Roundup January 2024
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A sobering look at the economy, PFAS regulations continue, blue-ringed octopus key to sustainable energy, and black-mass recycling. All news found here: https://www.chemicalprocessing.com/industrynews Read by Executive Editor Jonathan Katz.Por chemicalprocessing
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Faster Ways To Train Chemical Operators
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The discussion revolves around operator training efficiency in the industry. Despite decades of training, companies often lack feedback on its effectiveness. New technologies like simulators and virtual reality offer objective ways to measure and improve training. Identifying and addressing deficiencies is crucial, similar to the aviation industry'…
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Welcome to the In Case You Missed It edition of Chemical Processing’s Distilled Podcast -- This podcast and its transcript can be found at chemicalprocessing.com. I’m Traci Purdum, EIC of Chemical Processing. In Case You Missed It brings the written word to life. In today’s episode, I will be reading a column from contributing editor Dirk Willard. …
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Predicaments can crop up at all stages of a chemical engineering career. Properly dealing with them without serious consequences often isn’t easy or sometimes even possible. You may face ethical as well as technical and political challenges. So, let’s look at a variety of these and how to deal with them. This edition of In Case You Missed It is bas…
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How To Avoid Alarm Rationalization Mistakes
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In this episode we focus on alarm rationalization mistakes, emphasizing the importance of addressing underlying problems rather than just managing the steady-state alarm rate. The discussion highlights the need for a clear operator action for each alarm, uniqueness in alarms, and the impact of alarm floods on human factors. The conversation explore…
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In this episode of Chemical Processing's Distilled Podcast, host Traci Purdum and guest Dave Strobhar, founder of Beville Engineering, discuss the importance of font size in operator training. They highlight concerns related to small font sizes on computer monitors used in control rooms, particularly with the increasing resolution of displays. Stro…
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Solutions Spotlight: Avoid Data Overload For Better Equipment Health
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In the chemical industry, understanding the health of rotating equipment is crucial for safety and productivity. Regular inspections, compliance with regulations and proactive maintenance are vital for equipment reliability. Ares Panagoulias, the director of condition monitoring and test lab at Hydro Inc., emphasizes the importance of data in asses…
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Operator Training: Unlock Efficiency, Enhance Safety By Reducing Emergency Procedures
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In this episode, Traci and Dave discuss the importance of reducing emergency procedures in chemical processing for better operator training and performance. They explore the benefits of streamlining procedures, emphasizing that about 90% of emergency steps are common across various situations. Dave advocates for simplified, condition-based procedur…
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Low-Cost Ways to Improve Operator Decision-Making
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Helping operators learn from past incidents and use pattern recognition to make better decisions faster will improve safety and efficiency.Por chemicalprocessing
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Solution Spotlight: Looking Inward at Chemical Industry Emissions
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SICK AG's David Inward on Chemical Industry Emissions MonitoringPor chemicalprocessing
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Podcast: Expert Insights on Calculating Operator Needs in The Chemical Industry
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In this podcast episode, Dave Strobhar discusses an innovative approach to calculating operator needs and the impact of automation on staffing in the process industry. He emphasizes the importance of assessing the consequences of tasks not being performed rather than just counting tasks. Special conditions and cross-training are also explored as fa…
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Chemical Processing Notebook: PFAS Regulations and the Supply Chain
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Chemical Processing Notebook is a new column and associated podcast presenting talking points from various industry experts on a wide range of topics. This first CP Notebook column focuses on the impact PFAS regulations are having on the supply chain, from the upstream chemical producers to the downstream manufacturers using per- and polyfluoroalky…
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Episode 30 Podcast: Unlocking Effective Alarm Management
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In this episode, we're tackling the misconceptions around alarm targets and operator workload. Dave Strobhar debunks the myth that hitting a specific alarm target means operators are maxed out. He emphasizes that these targets are tools to assess alarm systems, not workload indicators.Por chemicalprocessing
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Solution Spotlight: Race-Ready Project Development Gives Chemical Plants an Edge
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In the evolving world of chemical processing, companies face a formidable challenge as they strive to keep pace with ever-evolving industry demands, develop novel formulations and deliver innovative products to market. Meeting customer needs often requires adjustments to production processes, including new plants, facility expansions and equipment …
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Solution Spotlight: Alternative Fuels Pose Flow-Metering Challenges
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The physical properties of hydrogen differ highly from other gases. Plant operators are therefore faced with major challenges due to the necessary adaptations that need to be made. To help us understand the challenges and options available, Chemical Processing spoke with Frank Flow, head of analyzer products and chemical industry at Flexim Americas…
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Podcast: Study Reveals Advanced Process Control Can Degrade Operator Skills
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In this podcast episode, Traci and Dave discuss a study that shows advanced process control (APC) can lead to a degradation of operator skills. The study found that after just a week of using APC, there was a 10% loss in skill level, and after two weeks, there was a 50% loss. The data suggests that operators should periodically run the plant withou…
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Solution Spotlight: Process Monitoring Maintains Productivity, Mitigates Downtime
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Analytical equipment needs to be robust, reliable and responsive in order to detect change and enable corrective action. It also should be easy to use and provide high uptime. When considering process organics monitoring, there’s a lot to unpack. To help make sense of all the capabilities, Chemical Processing spoke with Amanda Tyndall, senior produ…
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Solutions Spotlight: Proper Communication Devices Are the Key to Safety
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Keeping workers safe in hazardous environments requires constant communication. Add to the equation that many locations are also harsh industrial settings means ensuring the right communication equipment is appropriately rated while providing the needed functionality is paramount. To better understand how to select the right equipment, Chemical Pro…
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Podcast: Cybersecurity Requires Teamwork And Dispelling The Air Gap Myth
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In this final episode of our three-part cybersecurity series with Matt Malone, ICS/OT cybersecurity consultant at Yokogawa, we talk about team strategy and old notions.Por chemicalprocessing
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Podcast: Cybersecurity -- Don’t Get Caught In Your Underwear
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Malware programs or endpoint protection programs are great tools. But in the same way that if you're a king sending an army out to battle, you're not going to have your soldiers storming the battlefield in a helmet and their underwear.Por chemicalprocessing
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Solution Spotlight: Tips To Manage Cyber Risks
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Part one of a three-part series aimed at helping you develop a sound cybersecurity plan focuses on assessments and training.Por chemicalprocessing
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Solutions Spotlight: Proper Training, Equipment Are Keys To Safe Operations
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In this episode, we're going to try and get our arms around understanding and addressing risks and how proper equipment and training are key for safe operation in hazardous areas. Joining me to share his expertise is Ryan Brownlee, Global Compliance and Technology Consultant with Pepperl+Fuchs. In that role, he provides guidance in regard to curren…
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Solutions Spotlight: Structured Workflows Turn Data Into Action Items
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In this episode of Solution Spotlight Traci Purdum, executive editor of Chemical Processing, speaks with Floyd Baker, vice president of Antea, a global software and services company specializing in asset integrity management software with digital twin. Floyd has been working in the asset integrity management industry for his entire career of over 4…
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