Chemical Processing Distilled (chemicalprocessing)

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.

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.

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 unprecedented cybersecurity risk.

If you’re not already a subscriber to Automation Chat, you can subscribe to it here:

https://rokthejournal.podbean.com/

Part one of a three-part series aimed at helping you develop a sound cybersecurity plan focuses on assessments and training.

Solution promises to reduce sensor maintenance, improve process performance, and ensure a safe work environment in the chlor-alkali industry.

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. 

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. 

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.

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

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:

1. Simulation-based training correlated with better performance
2. Years of experience didn't necessarily predict test scores
3. The test can be used to benchmark and improve training programs

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 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.

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.

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.

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.

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.

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.

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.

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

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

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.

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 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. 

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.

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.

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.

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.

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. 

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.

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.

Executive Editor Jonathan Katz catches us up on what's new in the chemical industry.

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.

 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 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.

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

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. 

Helping operators learn from past incidents and use pattern recognition to make better decisions faster will improve safety and efficiency.

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

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. 

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.

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.

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

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.

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.

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

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.

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.

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.

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.

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.

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

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

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.

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 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

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.

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.

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.

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.

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. 

SICK AG's David Inward on Chemical Industry Emissions Monitoring 

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.

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.

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.

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.”

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 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.

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.

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.

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.

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.

This news roundup ponders an elevator to space and questions Chemours ethics. 

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.

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.

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.

This Minute Clinic episode offers straight-forward solutions to help operators make better decisions. 

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.

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.

Efficient conveying solutions that protect workers from hazardous dust, fumes and odors.

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.

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. 

In today’s Minute Clinic, we learn about alarm redundancy without alarm duplication. 

Many companies use targets to drive design and that can lead to negative consequences.

In this Minute Clinic, we learn how to calculate total operators required to cover a post position. 

Diagrams and line labeling could save thousands of dollars when it comes to operator performance.

In this Minute Clinic, we tackle font size requirements in regard to alarm management.

What are human factors? Dave Strobhar -- founder and principal-human-factors engineer for Beville Engineering – defines human factors and offers sound advice going forward.