Chemical Processing Distilled: Recent Episodes
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The Chemical Processing Distilled podcast extracts essential elements to serve engineers designing and operating plants in the chemical industry.
Emerson's Michael Machuca explains how non-intrusive flow, temperature, corrosion and acoustic monitoring help chemical manufacturers boost safety, reliability and sustainability without cutting into pipes or halting production. Sponsored by Emerson
This month: fatal H2S release investigation findings, the final Conyers warehouse fire report, ACC's pushback on Brazil tariffs and a call for unified EPA-OSHA chemical safety rules and a reality check on AI in advanced process control.
In this episode Traci Purdum discusses Lynn Bergeson’s latest article "EPA, HHS Move Microplastics from Fringe Concern to Federal Priority"
July 15, 2026
For a long time, microplastics were treated as a recycling problem or a marine litter problem. That changed this spring. On April 6, 2026, two federal agencies moved on the same day in ways that push microplastics squarely into the compliance conversation.
Compliance Advisor columns.
In this episode of Chemical Processing's Distilled podcast, host Traci Purdum talks with Brad Buecker, senior technical consultant at Samco Technologies, about sodium softening — the workhorse treatment for industrial boiler makeup water. Buecker explains how hardness ions cause scale, why residual bicarbonate drives corrosive condensate return lines, and how to spot early warning signs of a poorly monitored softener. He shares real-world cases where bypassing softeners or delaying maintenance led to rapid boiler tube failures and six-figure losses, walks through the regeneration cycle and its common pitfalls, and compares sodium softening with reverse osmosis for higher-pressure systems.
Inconsistencies found across major references for common substances raise a harder question about what we assume we know and whether that's enough for design, operation and troubleshooting.
This podcast is an In Case You Missed It of the column that appeared on our site July 1. You can read it here.
Two hundred and fifty years ago this week, a group of delegates in Philadelphia signed their names to the Declaration of Independence. Today, we are going to talk about how chemistry made it all possible.
Olin and Huntsman announce a $12.5 billion tie-up, Evonik cuts 3,200 jobs and BASF's CEO warns of an oil shock — while Covestro bets on biology to clean up aniline production.
This episode digs into three plant-floor challenges that look simple until physics intervenes—bulk solids handling, heat pump-driven distillation savings and a water pump's mysterious cycling problem traced back to Bernoulli's principle.
Sources: "Bulk Solids and Powders: Flow, Storage and Conveyor Design in Chemical Plants" by Amin Almasi (Equipment Insights, June 8, 2026) | "Heat Pumps Slash Waste in Distillation Operations" by Thomas Kwan (Energy Saver, Feb. 16, 2026) | "Why This Water Pump Kept Cycling Off" by Andrew Sloley (Plant InSites, Jan. 26, 2026). All published on ChemicalProcessing.com.
Decades before the Strait of Hormuz closed and refineries started burning, process safety's great philosopher mapped exactly how pressure corrupts risk decisions.
This month's top stories cover an NRC environmental clearance for an advanced reactor in Texas, a deadly hydrogen sulfide incident under CSB investigation, SOCMA's regulatory priorities and new industry developments.
In every organization, informal hierarchies determine who gets heard, who gets interrupted and whose concerns get taken seriously. In process safety, the cost of getting it wrong is high. In this In Case You Missed It episode, Editor Traci Purdum reads a column from Lauren Neal, Chemical Processing's Workforce Matters expert. You can read the column here.
Experienced operators don't just know what to do — they know what to watch, regardless of how conditions change. That ability hinges on perceptual invariants: the critical relationships and variables that remain meaningful even as everything else shifts. Human factors engineer Dave Strobhar explains how identifying and reinforcing these invariants is the key to effective operator training. Rather than relying on years of trial and error, structured training programs — including targeted simulator use — can accelerate expertise dramatically. The goal is moving operators from simple stimulus-response behavior to true skill-based thinking that transfers across novel situations, closing the experience gap faster than ever before.
If you're a regular listener, you already know the deal — you work in this industry. You've spent your career in control rooms, on plant floors, in engineering offices, running calculations and managing processes that most of the world never thinks about. You know what a distillation column is.
But this episode is meant to be shared with a spouse, a parent, a kid, a friend — someone who's asked you "so what exactly do you do all day?" and you've struggled to explain it.
The complexity of the human body makes critical thinking an essential skill for doctors. It’s also important in our work. However, engineers often learn the value of critical thinking the hard way. Dirk Willard, by way of Editor Traci Purdum's spoken word, tells us not to over-concentrate on the zebras... and let the horses run free.
From a $144 million federal push to address microplastics in drinking water to a CEO transition at Dow and Edison Award wins for chemical giants, here's what moved the needle in April 2026.
Throwing operators into full simulator scenarios sounds thorough, but it can mask the one critical subtask they actually need to master. Human factors engineer Dave Strobhar argues that effective operator training starts by identifying which subtasks carry the highest consequences — loss of containment, asset destruction, major downtime — and drilling those specifically before integrating them into broader scenarios. Using real examples of failed steam-system isolations and a misallocated $500,000 simulator budget, Strobhar makes the case for focused, measurable training objectives over checkbox exercises. The goal isn't to simulate everything. It's to ensure operators get the one decision right when it counts.
In this episode of Chemical Processing's Distilled podcast, editor-in-chief Traci Purdum speaks with water treatment expert Brad Buecker about the dangers of the "water is water" mindset in industrial settings. Buecker shares real-world examples of costly boiler failures caused by ignoring water chemistry, explains how water's near-universal solvent properties create scaling and corrosion risks and highlights how geography and climate shape treatment needs. He stresses that single water analyses are insufficient — comprehensive, historically collected data is essential for proper system design. The conversation also covers microbiological fouling, Legionella risks and the growing pressure on surface water supplies.
After nearly two decades, Seán Ottewell retires from Chemical Processing, leaving behind a legacy that spans battlefield bones, Neanderthal adhesives and one particularly memorable hedge. In this episode, Editor-in-Chief Traci Purdum highlights some of his best work...including taking a tinkle on his neighbor's landscaping.
Supply chain shocks from the Iran conflict, a contested overhaul of chemical safety law, an ethylene oxide rollback and a green chemistry advance — the month's biggest stories summarized by Executive Editor Jonathan Katz.
Cross-training process plant operators sounds simple, but execution is often flawed. Human factors engineer Dave Strobhar explains that effective cross-training must be based on job complexity and demonstrated competency — not arbitrary time requirements. Common pitfalls include inconsistent crew procedures that cause negative transfer of training, inadequate alarm management for operators returning to console roles and subjective assessments that fail to verify true proficiency. Decision-making exercises offer a low-cost way to prepare crews for high-stakes, low-frequency events. Looking ahead, Strobhar predicts automation and AI will fundamentally reshape operator roles, demanding more technical knowledge and sharper system-oversight skills from tomorrow's workforce.
In this bonus episode, Executive Editor Jonathan Katz highlights main points from his recent interview for his Chemical Processing Notebook series.
Eric Byer lives and works in Washington, D.C., where he fights for more than 400 companies that make up the Alliance for Chemical Distribution. As CEO and president of ACD, he backs the interests of chemical distributors by lobbying on issues such as fair trade policy, rail reform, and chemical safety. He has testified before Congress on several of these issues and keeps his members informed on the trends and legislation that affect their bottom line. I recently spoke with Byer as the Iran war was escalating and his members were already feeling the pressure.
Corrosive acids, erosive slurries, viscous polymers, fluids with variable conductivity — these are the kinds of process streams that prove most challenging. Selecting the wrong technology or materials can mean frequent failures, costly downtime or, worse, a safety incident. Electromagnetic flow meters — also known as mag meters — have been a workhorse of the chemical industry for decades. But there's a lot more nuance to applying them well in tough services than most people realize, and some newer developments in the technology haven't gotten nearly the attention they deserve.
To better understand all that mag meters have to offer, Chemical Processing sat down with Tim Lellman, electromagnetic flow product manager at KROHNE. This episode was sponsored by KROHNE
Workforce Matters columnist Lauren Neal explains what happens when experience stops sharpening judgment and starts dulling curiosity. The comfort and danger of “we’ve seen this before.”
You can read the full column here.
This was read by Editor-in-Chief Traci Purdum.
Executive Editor Jonathan Katz reviews this month's chemical industry news, which covers a landmark tariff ruling, Dow's AI-driven layoffs, the rollback of the EPA's Endangerment Finding, BASF's India expansion and a new leader for global plastics treaty talks.
Chemical processing operators need training that mirrors real-world conditions, not idealized scenarios. The final six guidelines from Walter Schneider's research emphasize maintaining motivation through consequences, presenting complex contexts with distractions, intermixing tasks to build switching skills, and incorporating time pressure. Training should capture expert strategies that minimize workload—like focusing on key parameters rather than monitoring everything—and teach operators to triage actions during high-stress situations. By including realistic elements such as weather conditions, phone calls, and multiple simultaneous problems, training programs help operators learn what to prioritize and when. This naturalistic approach accelerates skill development for managing chemical plants' complex, fast-moving challenges.
eChem Expo, recently acquired by Chemical Processing’s parent company EndeavorB2B, returns April 7-9, 2026, in Kingsport, Tennessee. Conference Director Damon Shackelford discusses the event's evolution from a regional gathering to a comprehensive three-part experience featuring an expo floor with nearly 200 vendors, professional conference sessions and technical seminars. This year's theme, "Energizing Growth and Resilience in a Competitive Landscape," addresses critical industry challenges including workforce development, AI integration, operational excellence and safety. New for 2026: inspector recertification credits meeting API guidelines. The market-led conference builds content through 100-plus stakeholder interviews with major manufacturers like Eastman Chemical, BAE Systems and BWXT, offering affordable professional development within driving distance for attendees from Cincinnati to Atlanta.
From light-driven catalysts to EPA debates, chemical sector balances technological advances with safety, economic and environmental challenges. Editor-in-Chief digs into what the audience was reading.
The chemical industry faces flat growth, formaldehyde regulation debate, Venezuela oil investment push, winter storm threats and a cheesy viral moment.
Global chemical regulatory ‘best guess’ for 2026 amid political shifts, litigation and evolving U.S. and European Union policies.
Each year, Bergeson & Campbell, P.C., its global consulting affiliate The Acta Group, and consortia management affiliate B&C Consortia Management, L.L.C., prepare a summary overview of things to come in the new year. We are pleased to present our Forecast 2026. Our global team of chemical experts works hard each year to summarize our collective best guess on what to expect in the new year regarding global industrial, agricultural and biocidal chemical regulatory and policy initiatives. This year's analysis was no easy feat, given the general capriciousness of the world in which we live, global geopolitical and trade tensions and the looming 2026 midyear elections.
In this Chemical Processing podcast, Traci Purdum and Dave Strobhar discuss training guidelines for operators. They cover five of 11 guidelines based on Walter Schneider's research: promoting consistent processing to build automaticity (where tasks become automatic), designing training for repeated practice of critical skills, avoiding memory overload through reference materials, varying training conditions to match real-world scenarios, and maintaining active trainee participation. Dave emphasizes practical applications like alarm recognition and emergency response training. The discussion highlights how proper training helps operators perform effectively under stress by developing automatic responses to critical situations rather than relying solely on conscious thought.
Cautiously Optimistic Despite Near-Term Headwinds
U.S. chemical sector shows resilience with long-term growth potential amid trade uncertainties and uneven recovery.
Martha Gilchrist Moore, chief economist for the American Chemistry Council, offers her predictions for the coming year.
Editor-in-Chief Traci Purdum reads the column.
You can read the article here.
Alexandra Savino explains why new data showing recycled plastics contain more hazardous substances than virgin materials is driving Extended Producer Responsibility reforms that link compliance to chemical performance.
Key Highlights
EPR now includes chemical safety, increasing scrutiny on contaminants like metals, PFAS and PAHs in post-consumer recycled plastics.
Upstream accountability is growing, with regulators and brand owners requiring chemical producers to verify product safety and recyclability data.
Proactive compliance creates opportunity, as processors that audit, reformulate and improve traceability can gain an advantage in chemically safe recycling.
Read the column here.
Welcome to the year-end edition of Distilled News. To wrap up 2025, we will review some of the top stories coming from the chemical industry over the past 12 months.
This episode of Distilled features the final 2025 Vaaler Award winner: Flowserve's INNOMAG TB-MAG Dual Drive. This sealless pump technology provides secondary containment through the pump itself rather than the motor, unlike canned motor pumps. The system prevents catastrophic leaks of toxic and corrosive fluids while handling up to 30% solids. Nick Rentzelos, the technology's inventor and Flowserve's director, explains how the maintenance-free design addresses the skilled workforce shortage and stringent safety regulations. The pump features hydrodynamic silicon carbide bearings that don't wear, requires no seal replacement or shaft alignment, and easily retrofits into existing facilities. Energy-efficient carbon fiber containment shells replace traditional metal cans, reducing friction and motor drag while keeping hazardous fluids completely isolated from electrical components.
Yokogawa's Vaaler Award-winning reinforcement learning algorithm reduces implementation time, balances plant objectives and achieves rapid learning in trials.
Factorial Kernel Dynamic Policy Programming, or FKDPP, a reinforcement learning AI developed by Yokogawa and the NARA Institute of Science and Technology and applied by Yokogawa to process industries is the first reinforcement learning AI to autonomously control complex chemical processes, FKDPP complements manual and conventional control methods like PID and advanced process control.
Karthik Gopalakrishnan, part of the digital transformation, smart manufacturing, artificial intelligence, cybersecurity and industrial automation team at Yokogawa, discusses the award-winning tech with EIC Traci Purdum
Vaaler Award winning technology allows operators to forgo traditional insulation systems and all the associated labor, materials, inspection, and maintenance expenses in favor of a spray-applied coating that retains process heat, protects personnel, and eliminates corrosion under insulation.
Editor-in-Chief Traci Purdum chats with Neil Wilds, global product director, Corrosion Under Insulation Testing, to learn how this innovation earned a Vaaler Award. Neil is affiliated with the Sherwin-Williams Protective and Marine Products line.
Deloitte forecasts 0.2% production decline as industry faces "confused sea state," German sentiment plummets, and environmental groups challenge Trump's chemical plant exemptions.
Welcome to Distilled News, where Jonathan Katz, executive editor of Chemical Processing, looks back at the top stories each month on Chemicalprocessing.com.
There are many things to consider with flow measurement technology, including prioritizing safety features for hazardous processes and remote locations. Additionally, the proper instrumentation prevents leaks and environmental incidents while supporting efficiency and operations. To help us better understand all things involved, Chemical Processing spoke with David Wright, global product manager at Emerson. In his role, he supports flow measurement products in a variety of industries, including oil and gas, chemical, refining and food and beverage.
This episode is sponsored by Emerson.
Two years ago, an operator was told she wasn’t “management material.” But only six months later – new manager, new opportunity – she was leading a cross-site safety improvement project.
Her potential didn’t change. The lens did.
In chemical facilities, we monitor pressure to the decimal. We track every deviation in flow, temperature and system response. But when it comes to people — especially how we judge their potential — we’re often running on hunches, habit and hierarchy.
Editor Traci Purdum reads the column "Leadership Potential Isn’t Fixed, It’s Shaped by Who’s Looking" from Workforce Matters.
Executive Editor Jonathan Katz gets all spooky with this month's news. Major chemical companies accelerate development using artificial intelligence and robotics, even as economic pressures force European plant shutdowns and project delays.
In this sponsored Solutions Spotlight, KROHNE experts discuss flow measurement technologies for chlor-alkali processes, covering mag meters, Coriolis meters, entrained gas management and safety integrity levels.
Three Key Takeaways
- Virtual reference technology eliminates leak paths in mag meters by using a non-wetted grounding methodology, reducing costs and maintenance risks in corrosive applications.
- Straight-tube Coriolis meters offer advantages over bent-tube designs: easier installation, less pressure drop, reduced abrasion, simpler cleaning and competitive pricing with custody transfer accuracy.
- Entrained gas management is essential for process reliability — it keeps Coriolis meters measuring during two-phase flow conditions and provides early warning of upstream equipment problems like cavitating pumps or failing seals.
This episode is sponsored by KROHNE
In this episode, Traci Purdum and Dave Strohbar explore why traditional training approaches fail operators in chemical processing plants. They examine misconceptions about practice, simulator fidelity, motivation, accuracy versus acceptable performance, early assessment reliability, and the gap between theory and practical skills.
This episode discusses how AI accelerates materials discovery in the chemical industry. While challenges exist—messy data, black box models, and skills gaps—AI enables simulations that once took days on supercomputers to run in seconds on laptops. Young advocates a "crawl, walk, run" approach for implementation, starting with low-stakes trials before full integration. He envisions an "in silico-first" future where materials are screened virtually before physical testing, dramatically reducing R&D timeframes from years to months.
Environmental consultant Dave Russell recounts his involvement in the Ecuador lawsuit against Texaco/Chevron over Amazon rainforest contamination. Hired in 2003 to assess cleanup costs, Russell produced a $6.1 billion estimate based on unverified assumptions—a "SWAG" (Scientific Wild Ass Guess) that helped secure a $9.5 billion judgment. However, his soil samples revealed the primary toxins were missing, and ongoing contamination came from Petro Ecuador, not Chevron. The case unraveled when Chevron exposed massive fraud.
In this bonus episode, which was originally recorded for Chemical Processing's sister brand, Processing, KHRONE's Joe Incontri, director of marketing, discusses the company’s flow meter lineup.
EPA fires staff over dissent letter while industry groups push for faster chemical reviews before 2026 TSCA reauthorization deadline are among the top news stories in September 2025.
Executive Editor Jonathan Katz reviews all you need to know.
With 5 million tons of new polyethylene capacity hitting saturated markets and Trump's legislative agenda threatening green investments, chemical firms are scrambling to adjust, says Maine Pointe's Stephen Ottley.
Joe Incontri from KROHNE explains how radar level measurement devices work using high-frequency time measurement technology. He covers radar's advantages over ultrasonic alternatives, including better resolution and smaller antennas, while addressing challenges like density measurement limitations and interference from dust or agitated surfaces. The conversation highlights radar's cost-effectiveness and simplified setup processes, concluding with KROHNE's pioneering role in introducing FMCW radar technology in the early 1980s and their 50-year industry experience.
Consider safeguarding senior leaders from burnout in high-stakes projects as an extension of design for safety.
In Case You Missed It brings the written word to life. In today’s episode, Chemical Processing's Editor in Chief, Traci Purdum, will be reading an article from Lauren Neal, CP’s Workforce Matters Columnist. Who Protects the Protectors?
Which was published to chemicalprocessing.com on Sept. 3, 2025
Executive Editor Jonathan Katz reviews the top news for August 2025:
Eastman Chemical faces setbacks as it appeals the Trump administration's cancellation of $1.2 billion in funding for its Texas plastic recycling facility, while seeking alternative locations for its methanolysis technology. International climate efforts stalled when UN plastics treaty negotiations in Geneva failed to reach an agreement among 2,600 participants from 183 countries over production limits and funding responsibilities. Safety concerns persist at Didion Milling, where federal investigators report unaddressed recommendations eight years after fatal 2017 explosions. On a positive note, researchers have developed a promising water-based electrochemical method for ammonia synthesis using palladium membranes, potentially replacing alcohol-based processes.
If you spend enough time dealing with particulate solids, you’ll encounter very sticky solids and end up spending countless hours cleaning out a plugged distributor, opening a discharge chute or banging on the vessel to get the solids to flow. There are many reasons solids clump or stick to surfaces. Let’s face it: sticky solids need special attention. But first, we must identify the source of the stickiness.
In this episode, Traci Purdum, CP's editor-in-chief, reads a column from Solids Advice columnist Tom Blackwood.
You can read the column here.
While bubble-cap trays excel in low-leakage and turndown applications, operators should also be aware of additional challenges such as vapor blowing that can occur at high vapor rates and low liquid rates.
This episode discusses the complex challenge of managing PFAS (per- and polyfluoroalkyl substances) chemicals amid evolving regulations. Phil Molé from Velocity EHS explains that companies struggle to identify PFAS in their inventories due to vague product names and changing chemical compositions.
PFAS are persistent, bioaccumulative toxins that resist biodegradation and contaminate the environment, driving regulatory action across federal, state and international jurisdictions. Companies must prioritize phase-outs based on their operating locations and applicable regulations, such as EPA's Form R reporting requirements (with a low 100-pound threshold for PFAS) and EU REACH regulations.
In a recent episode of Amplified from Control magazine, host Keith Larson interviews Brian Reynolds (Honeywell CTO), Alicia Kempf (Honeywell Director Offering Management), and David Patin (ExxonMobil TDC Modernization Program Lead Engineer). The discussion took place at the 2025 Honeywell User Group meeting, celebrating 50 years since the first Honeywell TDC 2000 installation in 1975.
The conversation traces the evolution of distributed control systems from centralized cabinet rooms in the 1970s-80s to today's truly distributed architecture with Universal IO and virtualization. Key developments include automated device commissioning, which reduced loop checks from hours to minutes, and the ability to modernize legacy systems on-process without shutdowns.
This week's episode includes exclusive, unpublished content related to Trump administration's R&D cuts within the EPA and their potential effects on environmental research priorities.
Recent chemical industry developments highlight regulatory tensions and operational changes. EPA workers are protesting new leadership under Zeldin, with 139 employees placed on administrative leave amid accusations of science politicization and environmental justice program cuts. Trump granted the chemical industry a two-year EPA exemption, addressing industry concerns about previous regulations. Meanwhile, Braskem launched its $89 million Brave Future ethane carrier as part of fleet expansion, while Dow announced closures of three European plants by 2027 to improve margins. Researchers developed a breakthrough catalytic method converting biopolymers into recyclable high-performance plastics.
Using new 3D fluorescence imaging, scientists have identified how aging polymer coatings generate corrosive compounds, leading to improved preservation strategies for cultural artifacts.
In today’s episode, Editor-in-Chief Traci Purdum will be reading a column from editor-at-large Seán Ottewell – “Why Protective Coatings Damage Metal Artifacts — and How to Fix It,” which was posted to our site on July 7, 2025
Get your sea legs ready. The economy is getting choppy, according to Martha Gilchrist Moore, chief economist and managing director, economics and statistics at the American Chemistry Council (ACC).
Are you leaving $7.7 million on the table? A single chemical plant identified annual energy savings worth that much through an analysis that took just months to complete. The payback period? Less than two years. The solution? None other than your chemical engineering 101 heat integration through pinch analysis and heat exchanger network optimization.
Editor-in-Chief Traci Purdum reads the latest Energy Saver column written by Thomas Kwan.
The Trump administration has proposed to eliminate the U.S. Chemical Safety and Hazard Investigation Board by October 2026, citing fiscal responsibility and redundancy. Industry experts oppose this move, warning it would remove crucial disaster prevention oversight despite the agency's modest $14 million budget. Meanwhile, recycling advances continue: Eastman expanded molecular recycling operations to 110,000 metric tons annually in Tennessee, while BASF launched Europe's largest battery recycling plant, processing nearly 40,000 EV batteries yearly. On the innovation front, Department of Energy researchers developed a photosynthesis-inspired catalyst that selectively converts CO2 into formate using light, potentially revolutionizing industrial chemical production by avoiding unwanted byproducts that plague current conversion methods.
Did you know that today — June 23 — is International Women in Engineering Day (INWED)? Launched by the Women’s Engineering Society (WES) in the UK in 2014, the event has since grown into an internationally recognized awareness campaign celebrated by various organizations, institutions, and individuals around the world. Each year, INWED adopts a specific theme to focus on women’s contributions to engineering and STEM. This year’s theme is “Together We Engineer.”
From the days of Cleopatra to contemporary chemical engineers, we look at the women who transformed modern life through innovations touching nearly every aspect of human existence.
INWED2025
In this episode, Traci and Dave focus on training evaluation as the final component of instructional system design. Dave explains that evaluation has two aspects: specific (assessing whether students learned what was taught in a particular course) and global (determining if training improves actual job performance).
The key insight is that evaluation methods should align directly with learning objectives. If objectives are correctly written to be objective and measurable, they define how students should be evaluated. Most companies fail at proper evaluation, relying on subjective assessments rather than objective testing.
High-fidelity simulators and process data can measure actual performance improvements in real-world transfer evaluations. However, evaluation should focus on system performance rather than individual blame.
In Case You Missed It brings the written word to life. In today’s episode, Editor-in-Chief Traci Purdum will read an article from Lauren Neal, Chemical Processing’s Workforce Matters columnist. This column “Small Acts, Big Impact: How Micro-Behaviors Shape Teams” was published to our website June 4, 2025
You know that feeling. You’re in a team meeting, presenting a solid idea, and someone smirks. Another person rolls their eyes. Then silence.
No one says a word.
That’s a micro-behavior. A subtle action that doesn’t show up in the org chart or the risk register but does show up in the culture and your team’s morale, retention and performance.
In this episode, Executive Editor Jonathan Katz reviews the top news stories for May 2025.
Trump's budget cuts and EPA changes reshape the chemical industry amid expansion.
In Chemical Processing's Distilled Podcast, we discuss flaws in operator training, focusing on "time to train." Companies can waste millions of dollars by not optimizing training duration, often using fixed-length programs regardless of trainees' prior experience. Feedback loops to adjust training time based on individual competency and learning objectives are imperative. Indeed, proper assessment could identify struggling trainees and high performers who could be fast-tracked.
This episode from Chemical Processing's Distilled podcast shares industry best practices for chemical plant reliability and maintenance. Key recommendations include understanding equipment failure modes through predictive maintenance techniques like vibration analysis and thermography, developing balanced preventive maintenance programs that avoid over-maintaining equipment, and conducting thorough root cause analysis using methods such as 5-why analysis and fishbone diagrams.
With Easter just behind us and chocolate consumption hitting its second-quarter 2025 peak, it’s a good time to reflect on the theological and processing developments that have got us where we are today.
In this In Case You Missed It Episode, Chemical Processing's Editor-in-Chief Traci Purdum brings the written word to life, and Seán Ottewell, editor-at-large, provides the story.
The original column was posted to the site on May 5, 2025.
Chocoholics unite!
Executive Editor Jonathan Katz highlights the news of April 2025.
Trump's EPA eases regulations while confusion stalls recycling innovation and Dow delays climate investments.
Olivia followed all the right steps. As a chemical engineer at a major manufacturing plant, she had a mentor – a senior colleague who gave her great advice on career growth, technical skills and workplace challenges. She networked, took on projects and worked hard.
Yet, after years of effort, she was still in the same role, watching others get ahead.
Then she met Rahul, a senior executive who didn’t just advise – he advocated.
This In Case You Missed It episode features a column by Lauren Neal, Chemical Processing's Workforce Matters columnist. It is read by Editor-in-Chief Traci Purdum.
This Earth Day, the chemical industry finds itself at a crossroads in an era of deregulation.
Growing up in Cleveland, Ohio, you learn early on all the things that put the city on the map. Two local cartoonists, Jerry Siegel and Joe Shuster, gave the world Superman. The city pioneered traffic safety with the world's first electric signal in 1914, forever changing how streets operate. The Rock and Roll Hall of Fame calls Cleveland home, as does the house from "A Christmas Story," where the warning "You'll shoot your eye out" is synonymous with Red Ryder BB guns. And yes, our river caught fire — more than once.
In this episode, Traci and Dave discuss the importance of practice in operator training programs. Practice is often overlooked despite being crucial. Realistic scenarios that mimic real-world conditions, including time constraints and environmental challenges, are beneficial to anchoring lessons learned. Feedback loops are also necessary to evaluate individual performance and improve training programs. The new concept of micro training, in addition to having operators teach others, helps operators continuously practice their skills.
In a recent episode of Ear on Processing from Chemical Processing’s sister brand Processing, chief editor, Jesse Osborne, sat down with Greene Tweed’s business development manager for life sciences markets. They discussed the importance of sustainability for process manufacturers and outlined how Green Tweed’s FFKM products are assisting in that regard.
Enjoy this bonus episode of Distilled.
Trade organizations express concern over rising costs and supply chain disruptions. This episode takes a look at how the Trump administration's whiplash tariffs will impact the chemical industry.
A power shift is underway at the EPA as former American Chemistry Council representatives are positioned to assume key roles under the Trump administration, potentially reshaping the agency's regulatory approach. Meanwhile, safety concerns remain paramount as the U.S. Chemical Safety Board continues investigating a deadly reactor explosion at a Louisville food additive plant that claimed two workers' lives. The CSB has also released new reports analyzing recent industrial accidents to prevent future incidents. In corporate news, major chemical and energy companies including BASF, Chevron, DuPont, and Shell have announced significant executive leadership changes that could influence industry direction in the coming months.
Electromagnetic flow meters are volumetric flow meters that use electromagnetic induction to measure liquid velocity. This measurement method is highly accurate at measuring water-based fluids as they pass through a pipe. They are cost-effective, long-lasting and compatible with existing technology. However, there are things to consider before investing in this technology.
Chemical Processing chatted with Joseph Incontri, director of marketing North America at Krohne, to help us understand the pros and cons.
In this episode, Traci and Dave discuss how learning objectives fit into instructional system design. Learning objectives should be measurable, not subject to interpretation, and directly testable. Unlike vague goals like "understand distillation," effective objectives specify demonstrable skills.
I’ve never seen a piece of equipment that didn’t do what it was supposed to. That doesn’t mean it did what its user thought it could do. In solids processing, we often struggle with a piece of equipment because it was a poor selection or installed improperly.
There are eight specific steps to ensure your equipment choices accurately represent your product and operations.
Column "8 Steps for Solids Equipment Selection" by Tom Blackwood and narrated by Traci Purdum.
An Inuit man who was left to his own defenses in the Arctic after being exiled from his family had to fashion a knife out of his own frozen feces…. In this episode, Editor-in-Chief Traci Purdum talks about the Ig Nobels and improbable research that makes you laugh and then makes you think.
Washington leaders visited the accident site on the two-year anniversary of a train derailment that contaminated air, soil and water. A landmark step toward promoting sound science and advancing U.S. competitiveness has also been taken. LyondellBasell’s Houston refinery, in operation for over a century, is closing due to high maintenance costs and shifting market dynamics.
Job analysis is a crucial component of instructional system design that identifies essential skills and knowledge needed for a job, moving beyond inefficient shadowing methods. However, it's often poorly executed or skipped entirely. Effective analysis should focus on specific behaviors, consider environmental factors, and adapt to technological changes like automation.
"Teamwork matters. Teamwork saves lives." That’s the battle cry from Eduardo Salas, the Allyn R. and Gladys M. Cline chair professor in Rice University’s psychological sciences department, and Scott Tannenbaum, president at The Group for Organizational Effectiveness Inc.
This episode uncovers the ways teams can save lives. The deadly Pemex chemical leak serves as an example.
Work that began in the 1800s is still going strong with the help of a teacher, Motörhead and hypothetical, superheavy elements yet to be discovered.
In this news roundup, Executive Editor Jonathan Katz highlights significant policy shifts, with Trump's energy initiatives reversing environmental protections and renewable energy commitments. Chemical industry regulations face changes with TSCA reform and EPA appointments of former industry executives. Additional developments include expanded PFAS reporting requirements, biofuel research funding and Covestro's U.S. manufacturing expansion.
In this episode of Distilled, CP’s Editor Traci Purdum chats with David Strobhar, founder and principal human factors engineer for Beville Engineering. Dave is also the founder of the Center for Operator Performance. The two discuss Instructional System Design, a systematic training approach developed by the Air Force to create efficient, measurable, and effective training programs across diverse industrial workforces.
In today’s episode, Chemical Processing’s Editor-in-Chief, Traci Purdum, will be reading this year’s Chemical Industry Outlook, written by Martha Gilchrist Moore, chief economist and managing director of the American Chemistry Council, Washington, D.C.
Martha and the ACC have been offering Chemical Processing a glimpse into their economic crystal ball for several years. Here is what’s in store for 2025.
Welcome to our first episode of Chemical Processing's Distilled podcast in 2025. This podcast and its transcript can be found at chemicalprocessing.com. I'm Traci Purdum, editor-in-chief of CP.
I, like many folks, use the new year to reflect on the past year and find inspiration for the next 365 days during the “Bermuda Triangle” time between the holidays and New Year. You know those days that all mesh together, and you don't know whether it's Tuesday or Saturday, and you've just had a handful of cookies for breakfast? Well, I decided to listen to past episodes of Distilled. I came across many auditory pearls of wisdom, and I whittled them down to four things I plan to work on this year. Maybe you'd like to join me.
In his final news roundup of the year, Executive Editor Jon Katz highlights: Global plastic pollution treaty stalls amid negotiations. DuPont loses lawsuit secrecy bid. EPA closes PFAS chemical review loopholes. Bhopal lessons persist. Chemical facilities warned about winter safety risks.
As a technical expert in a chemical facility, your knowledge is the backbone of operations. However, as your responsibilities increase, transitioning from a purely technical role to one in leadership can be challenging. Developing an inclusive approach not only strengthens team cohesion but also boosts overall performance.
Here are five tips for how to evolve from a technical expert into an inclusive leader.
Based on a column from Lauren Neal “Technical Expert to Inclusive Leader: How to Evolve Your Leadership Style”
Read by Traci Purdum, editor-in-chief, Chemical Processing
Her journey exemplifies professional growth through curiosity, adaptability and seizing unexpected opportunities.
Anne Berg, vice president of Manufacturing, Agricultural Solutions Americas at BASF, was recently inducted into the Women in Manufacturing Hall of Fame. Her remarkable 28-year career spans multiple countries and roles. Starting as a process development engineer in Germany in 1996, she has worked in manufacturing leadership positions in Germany, Belgium, Spain, and the United States.
Grab a cup of coffee and spend a few minutes going over the top news in the chemical industry with CP’s Executive Editor, Jonathan Katz.
Election 2024 Recap: Chemical Industry Sees Regulatory Relief in Trump's Return
As manufacturers welcome a potential rollback of Biden-era rules, experts warn companies must still answer to shareholders and customers on environmental commitments.
Trump Selects Zeldin to Lead the EPA
Former New York congressman is expected to play a role in industrial deregulation, which could have a major impact on the process industries.
Trump Names Liberty Energy CEO Chris Wright as Next Energy Secretary
President-elect selects shale industry leader to head energy department, promising a new era of American energy innovation and global influence.
Chemical Processing Reveals 2024 Job Satisfaction and Salary Survey Results
Annual survey continues to highlight a healthy industry outlook among chemical engineering professionals.
CSB Is Like a Dog with a Bone Investigating Safety Cases
Chemical Safety Board clears backlog, tackles eight new hazardous incident investigations.
In the fast-paced world of chemical processing and operations, effective time management is not just a luxury — it’s a necessity. Engineers and operators often face complex tasks, tight deadlines and high-stakes environments with an extremely limited margin for error.
Implementing effective time-management strategies can significantly enhance productivity, reduce stress and improve overall job satisfaction, but how do you do it?
Written by Lauren Neal, Founder of Valued at Work
Read by Traci Purdum, editor-in-chief
Column can be found here.
As manufacturers welcome a potential rollback of Biden-era rules, experts warn companies must still answer to shareholders and customers on environmental commitments.
The chemical industry has been yearning for the Trump administration’s hands-off approach to regulations ever since Jan. 20, 2021, the day President Joe Biden took office. For chemical manufacturers, the return of Donald J. Trump to the White House symbolizes a momentous shift toward less regulation and bureaucratic oversight.
In Case You Missed It brings the written word to life. In today’s episode, I will be reading a column from editor at large Seán Ottewell – “Chemistry History Lesson: From Anti-Plague Elixirs to a Precious Nose That Wasn’t.”
Danish scientist Tycho Brahe took many of his experiments to his grave. However, researchers from the University of Southern Denmark have found clues that shed light on his mysterious work.
Read the column, which was posted on our site Sept. 6, 2024.
Read by: Traci Purdum, editor-in-chief
Written by: Seán Ottewell
Unlikely allies in sustainability, a fatal chemical leak, an averted dock-worker strike, and BASF’s hall-of-famer round out the top stories on reader lists. Executive Editor Jonathan Katz reviews what topped the list for our readers this month.
When it comes to pumping systems, efficiency must be viewed in terms of measurable savings (kilowatts, horsepower) and taken as a whole-system approach. Organizational buy-in and leadership support are crucial. To help us understand how best to achieve efficiency, Chemical Processing chatted with Dr. Gary Dyson, managing director of global engineering at Hydro. Dyson is responsible for thousands of pump designs carried out on upgrades and new equipment.
What truly makes an expert? It's not just about knowing more facts. Discover the 13 key characteristics that set real experts apart, from forming expectancies to mental simulations. Learn how these traits apply across industries and how you can cultivate expertise in yourself and others. Whether you're an operator, manager, or lifelong learner, this discussion on the nature of expertise will change how you think about skill development and decision-making in complex environments.
Chemical Processing's Editor-in-Chief, Traci Purdum, recently sat in on a roundtable of fellow editors and manufacturing alliances to discuss how industry is facing a significant challenge in recruiting both skilled and unskilled workers. Listen in as her fellow business journalists reveal tactics big-name companies are using to attract younger workers to manufacturing careers.
Today’s episode highlights Chemical Processing’s other podcast series, Process Safety with Trish and Traci. We recently celebrated five years with that brand, and to commemorate that achievement, we hosted a fun show that featured a talented crime writer and well-respected chemical engineer, Fiona Erskine. I like to think about her book series as a glimpse into what James Bond/Nancy Drew would look like as a chemical engineer.
What were the hot topics in September 2024? Executive Editor Jon Katz runs through all the attention-getters.
Our monthly roundup of trending stories on ChemicalProcessing.com focuses on what your peers were reading. Executive Editor Jon Katz does his best Walter Cronkite impression as he bring the news to life. If you want to follow along, here are the stories he highlights.
In the second installment of our five-part series on the chemical industry workforce, "Chemical Industry Workforce: Shaping Tomorrow's Talent," Dennis Banks, vice president of Syncrude Maintenance at Suncor Energy Inc., offers his definition of DEI.
“I grew up in a place where there were drive-by shootings — I have bullet holes in my childhood home,” says Dennis Banks, vice president of Syncrude maintenance at Suncor Energy Inc., who grew up in Detroit, went to college in Louisiana and now resides in Fort McMurray, Alberta, Canada. “Some people freeze in the face of chaotic situations. I don't view [many] situations as perilous. So, I'm able to maintain calm and composure in the face of a lot of adversity and chaos because of what I went through growing up.”
Vacuum conveying systems automate the movement of dry materials, offering numerous benefits in industrial processes. They improve safety by controlling dust, reducing spills and handling combustible powders more securely than pressure-conveying systems. These systems enhance quality control through consistent ingredient ratios and efficient packaging, which is crucial for consumer brand management and avoiding costly recalls.
However, there are considerations to factor in when selecting a system. To discuss the challenges and benefits of vacuum-conveying, Chemical Processing sat down with David Kennedy, business development manager at VAC-U-MAX. The following is an edited version of that conversation.
Objectively assessing operator knowledge and skills is important. The Center for Operator Performance developed a validated 47-question test on distillation knowledge administered across multiple companies. The test revealed variations in knowledge between companies and individuals, helping identify areas for improvement. The goal is to create more tests on different topics. Key findings include:
- Simulation-based training correlated with better performance
- Years of experience didn't necessarily predict test scores
- The test can be used to benchmark and improve training programs
While watching the movie "Christmas Vacation" for the 67th time, I finally realized that Clark Griswold was a chemical engineer. I leaped down the rabbit hole looking for more famous ChemEs in real life and movies. I found several.
The top trending news stories from August 2024 as reported on ChemicalProcessing.com.
Cheers! Whiskey Waste Becomes Biochemicals
A new method to extract valuable bio-based chemicals from whiskey distillery waste streams could be worth up to £90 million ($US 115 million) in global chemical manufacturing markets.
Rice Engineers Design Eco-Friendly Ammonia Reactor
New electrochemical process could revolutionize ammonia production, reducing carbon emissions and water pollution
BASF to Produce Bio-Based Ethyl Acrylate, Phasing Out Fossil-Derived Version
New product with 40% bio-content from grain sources to launch Q4 2024, reducing carbon footprint by 30% while maintaining specifications.
Get Ready for Our Special Workforce Series
CP’s upcoming 5-part series will provide insight into the state of the chemical industry workforce.
Deconstructing the Chemical Industry’s Skills Gap
An aging workforce, fierce competition for graduates and culture clashes: Inside the chemical industry's struggle to fill critical roles.
Level indicators and pressure applications are crucial in ensuring efficient operations and safety. From basic visual indicators to advanced electronic transmitters, the range of technologies available is vast and constantly evolving.
Chemical Processing chatted with Jason Kuzmiak, Chemical Industry Manager at VEGA Americas, to delve into the world of level measurement and pressure instrumentation, exploring the various solutions, the challenges faced in implementation and the factors that drive customer choices.
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: Winterization Goes Beyond Equipment
Articles referenced in this podcast:
Get Ready for the Next Big Freeze
Time to Prepare for Winter
Prevent Accidents During Subfreezing Weather
Winter Weather Dangers: Why Winterizing is Crucial for Chemical Plants.
Winter-proof Your Workplace to Prevent Slips and Falls
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 mobile technology, emerging technologies like virtual reality and evolving job expectations.
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 Operations Due to Hurricane Beryl -- Company says it's working to restore power to the plant.
- What Ditching The Chevron Deference Means for the Chemical Industry --TSCA advocates and adversaries must be relentlessly compelling, fact-based and thorough in advocating for their positions in a Chevron-free world.
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.
Here is the full column
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 years of hands-on engineering experience at electrical machinery manufacturing and apparatus service firms. He has a BS in Electrical Engineering and is a licensed professional engineer.
Read by Editor-in-Chief Traci Purdum.
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, citing examples like the Yom Kippur War and the Three Mile Island incident. Dave offers strategies to combat fixation, including the two-strike rule, testing hypotheses, shift changes, maintaining situational awareness, and fostering open team communication.
ChemicalProcessing.com
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 company’s set format.
This ICYMI episode revisits a column from contributing editor Dirk Willard. You can read the column here: https://www.chemicalprocessing.com/asset-management/economics/article/11297512/write-engineering-reports-right-chemical-processing
Read by Editor-in-Chief Traci Purdum.
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
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, Teresa Houck, executive editor and host of Automation Chat, digs deep into a study regarding advancing digital transformation in a time of unprecedented cybersecurity risk.
If you’re not already a subscriber to Automation Chat, you can subscribe to it here:
https://rokthejournal.podbean.com/
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, as well as the advantages of a five-crew rotation system that allows for dedicated training time. We also stress that facilities should focus on sending their trainers to "train the trainer" courses to improve the quality of their training programs and incorporate best practices from other industries, such as aviation and healthcare.
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 week or two developing the scope, estimating the cost and laying out the schedule. Then, when eyes pop over the price, the project is entombed in a folder.
However, every so often, a need appears, funding is found, and the fun begins. The situation can become intense where regulators are involved or a project suddenly becomes crucial to the company.
You can read the full column here, which was posted to ChemicalProcessing.com on May 24, 2021
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 as pivotal forces shaping industries, the chemical sector stands at a critical junction.
Bob Ross isn’t the only one to have happy accidents.
Accidental discoveries have significantly advanced the chemical industry and led to numerous groundbreaking innovations. These serendipitous findings have often paved the way for the development of new materials, processes and applications that have had a profound impact on various sectors.
Time is critical when tracking down hazardous substances. Whether it’s trying to mitigate safety incidents before they happen, comply with applicable safety and environmental regulations, or gather all the pertinent information during an emergency involving a chemical spill, fire or natural disaster, having an efficient way to trace every ingredient is paramount.
However, many chemical product names tell you nothing about the ingredients they contain. You need ingredient-level visibility of hazardous chemicals to not only keep your employees and surrounding community safe but also meet many regulatory requirements and everyday safety management obligations.
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 myths.
This In Case You Missed It podcast features Tom Blackwood's "Beware of Blending Myths" column that appeared on the Chemical Processing site Oct. 14, 2016. It is read by Traci Purdum, editor-in-chief of Chemical Processing. The original column can be found here:
https://www.chemicalprocessing.com/processing-equipment/powder-solids/article/11320694/powder-handling-beware-of-blending-myths-chemical-processing
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.
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.
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. Central to many operations, vacuum pumps are crucial for various chemical processes, from managing raw materials to distillation.
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 You Know Department: Neanderthals Were Smarter Than We Thought. Indeed, today's multi-billion-dollar adhesives industry can be traced back more than 50,000 years to Neanderthals first using multicomponent adhesives to make tools.
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-in-chief
URL: https://www.chemicalprocessing.com/home/article/11288741/project-management-workflows-matter-chemical-processing
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 guides and realistic teaming scenarios aid in developing teamwork skills. Continuous learning and improvement are essential for optimal team performance.
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, Chemical Processing spoke with Alec O’Keefe, regional product lead and Coriolis meter product specialist at Krohne Inc.
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.
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 automatic shutdowns. However, concerns about overreliance and security exist. Proactive measures involve maintaining situational awareness and implementing training drills. Automation of routine tasks for console operators improves efficiency and safety. Collaboration among operators, engineers and management is crucial for effectively managing upsets.
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. Unfortunately, a nifty-looking web site can make a firm seem impressive and much more capable than it actually is. You don’t want to discover the truth after a contract is signed.
Article can be found here: https://www.chemicalprocessing.com/home/article/11291433/engineering-advice-properly-vet-contractors-chemical-processing
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.
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's approach. Differentiating between console and field operators, the former presents more straightforward opportunities for measurement. Training programs should adapt to an operator's existing knowledge when learning multiple units, reducing time and improving efficiency.
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. This column “Career Advice: Master Cold Calls” appeared on our website in March 2022
Read by: Traci Purdum, editor-in-chief
Article link:
https://www.chemicalprocessing.com/asset-management/training/article/11288979/career-advice-master-cold-calls-chemical-processing
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 based on the original column by contributing editor Dirk Willard. It was published March 29, 2021, and can be found here: Correctly Cope with Career Challenges.
Read by: Editor-in-Chief Traci Purdum, Chemical Processing
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 explores challenges, such as changes in processing equipment and the significance of data analytics in improving alarm systems.
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. Strobhar mentions the military's Mill Standard 1472, specifying preferred character heights for legibility and readability. The conversation covers issues related to contrast, font color, and background colors. Strobhar emphasizes the impact on operator fatigue and accessibility, especially for aging operators wearing bifocals.
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 assessing equipment health. He advises using remote monitoring to prioritize maintenance and diagnose emerging problems before they become serious and costly events. Chemical Processing sat down with Panagoulias to learn more.
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 procedures to enhance operator response during high-stress situations. They also touch on the significance of testing procedures in the field, involving junior operators in the process, and the potential for automation in emergency response.
Helping operators learn from past incidents and use pattern recognition to make better decisions faster will improve safety and efficiency.
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 factors influencing operator requirements.
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 polyfluoroalkyl substances (PFAS) in their products.
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.
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 upgrades. The successful execution of such projects hinges upon comprehensive planning, particularly when it comes to evaluating process safety risks.
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 Corporation.
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 without APC to maintain their skills. The Center for Operator Performance is researching interventions such as simulators, micro-learning and improved graphics to address this skill degradation. The integration of APC into the operator's role is also discussed as a shift in the nature of their work.
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 product manager at Veolia Water Technologies and Solutions, which sponsored this episode.
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 Processing spoke with Ryan Brownlee, product manager and hazardous locations expert at Pepperl+Fuchs.
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.
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.
Part one of a three-part series aimed at helping you develop a sound cybersecurity plan focuses on assessments and training.
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 current and new technology and product compliance trends for industrial automation applications, especially for those targeting hazardous or classified areas.
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 40 years, with half of that time spent on the owner user side and the other half on services and technology.
No longer a warm-fuzzy concept, sustainability is increasingly becoming as good for the bottom line as it is for the environment. To explain how AI-driven solutions that target machine and process health can help with strategy and results, Chemical Processing spoke with James Newman, head of product and portfolio marketing with Augury, a production health solutions provider that combines advanced sensors with AI capabilities and human expertise.
For corrosion-resistant heat-transfer materials in harsh and high-temperature processes, there are additional requirements to consider. To help explain existing and emerging technologies to meet specific process and plant conditions, Chemical Processing spoke with Gregory C. Becherer, senior vice president of Twinsburg, Ohio-based CG Thermal.
Safety, accuracy and reliability are paramount in the development and testing of fine and specialty chemicals. Add to that the need for regulatory compliance, and it becomes clear that proper tools are needed. To understand how lab instruments can complement the process, Chemical Processing spoke with Mitesh Chhana, Regional Business Manager Lab Weighing, EMEA, at Sartorius, a provider of instruments and services for the biopharmaceutical, chemical and food industries.
When it comes to machine maintenance, digital tools promise a lot — from improving safety, meeting production targets and eliminating unplanned downtime to filling skill gaps and regulating supply-chain issues. But simply alerting users to machine malfunctions isn't enough to transform your business. To gain insight, Chemical Processing spoke with Tim Sykes, heavy industry machine health lead at Augury, a machine health solutions provider that combines advanced sensors with AI capabilities and human expertise.
Supply-chain issues, global competition and the need to deliver high-quality products are challenges facing many chemicals manufacturers today. To meet these challenges, you must keep track of inventory, improve operations, make better products and drive smart, sustainable growth. It’s a tall order but the right tools will help.
Utilizing maintenance data to make key business decisions results in improved equipment reliability, optimized costs, improved safety, and environmental impacts. However, there are many challenges due to a lack of know-how, resources, and data quality issues.
To understand and mitigate those challenges, Chemical Processing spoke with Manjish Naik, Product Manager at GE Digital.
Efficient conveying solutions that protect workers from hazardous dust, fumes and odors.
Grabbing samples of hazardous chemicals in liquid and gas states is challenging but necessary. Manufacturers rely on quality samples to ensure products specs and operators rely on this equipment to help them grab those samples. But not all sampling platforms are the same.
Solution promises to reduce sensor maintenance, improve process performance, and ensure a safe work environment in the chlor-alkali industry.
While liquid tank level is one of the basic measurements used in process plants, its importance cannot be overstated. Incorrect high level measurements can cause vessels to overflow leading to lost product, a safety hazard or an environmental problem. Incorrect low level measurements can burn out pumps and can cause problems with inventory control. Enter differential pressure level measurement, which infers liquid level in a vessel by measuring the pressure generated at the bottom of the vessel.
To better understand this long-standing technology, Chemical Processing spoke with Nicholas Meyer, Industry Marketing Manager, Yokogawa Corporation of America.
The use of surrogate testing is a valuable tool in ensuring that contained dust collectors are meeting several requirements including environmental, employee health and safety and production cleanliness and efficiency.
Traci Purdum, executive digital editor of Chemical Processing, spoke with David Steil, pharmaceutical market manager at Camfil Air Pollution Control, to better understand surrogate testing. David has a Bachelor of Science degree in safety and industrial hygiene. He spent more than 12 years with Wyeth Pharmaceuticals as a member of its corporate environment health and safety group. David is a member of the International Society of Pharmaceutical Engineering and the American Industrial Hygiene Association.
Pardon the pun, but check valves are fairly straight forward -- they ensure flow in only one direction. In most designs, the upstream fluid force pushes a spring-loaded poppet open, allowing flow. An increase in downstream or back-pressure force drives the poppet back into the seat, stopping reverse flow. But their simplicity shouldn’t be taken for granted. Chemical Processing spoke with Brian Strait, Business Development and Marketing Manager at Check-All Valve Mfg. Co., and learned that not all check valves are created equally.
One of the most commonly used compounds in the chemical industry is water – not only as a solvent in processing, but also as an energy carrier in the cooling or heating cycle. Monitoring water quality can predict performance and protect equipment.
Chemical Processing spoke with Amanda Scott, product management leader for the Sievers* product line at SUEZ --Water Technologies & Solutions, we discovered how implementing critical control points, such as total organic carbon (TOC) analyzers for monitoring closed-loop cooling water systems, can help ensure efficiency and productivity.
Many chemical companies are striving to improve the reliability of vacuum systems, lower total cost of ownership and meet regulatory requirements for emissions standards and noise reduction. To address these demands as well as specific vacuum technology problems, vendors are responding with novel applications of established equipment as well as new technologies.
Enter dry vacuum pumps. Chemical Processing chatted with Busch Vacuum Solutions’ Jason Stiel, Ph.D., chemical and pharmaceutical sales manager, about the benefits and challenges of dry vacuum pumps.
What are human factors? Dave Strobhar -- founder and principal-human-factors engineer for Beville Engineering – defines human factors and offers sound advice going forward.
This Minute Clinic episode offers straight-forward solutions to help operators make better decisions.
Diagrams and line labeling could save thousands of dollars when it comes to operator performance.
In this Minute Clinic, we learn how to calculate total operators required to cover a post position.