Metal Forming Industry Outlook: Bright and Resilient

The metal forming industry is one of the most vital and dynamic sectors of the manufacturing economy, producing a wide range of products for various industries such as automotive, aerospace, construction, energy, and medical. Despite the challenges posed by the COVID-19 pandemic, the metal forming industry has shown remarkable resilience and optimism for the future.

According to the latest Precision Metalforming Association (PMA) Business Conditions Report, metal formers expect a significant improvement in business conditions during the next three months. The report, based on a monthly survey of 115 metal forming companies in the United States and Canada, shows that 47% of participants anticipate an improvement in economic activity in the near term, up from 37% in January. Only 8% predict a decline, down from 13% last month, while 45% expect no change.

The report also reveals that metal formers are more confident about their current business situation, with 33% reporting an increase in net new orders in February, up from 28% in January. The percentage of metal formers with a portion of their workforce on short time or layoff decreased to 9% in February, the lowest level since March 2019.

The optimism of metal formers is supported by the positive trends in the broader manufacturing sector, which has been leading the economic recovery in the United States and Canada. The latest Purchasing Managers’ Index (PMI) from the Institute for Supply Management (ISM) indicates that the manufacturing activity expanded for the ninth consecutive month in February, reaching 60.8%, the highest level since February 2018. The PMI measures the health of the manufacturing sector based on five major indicators: new orders, production, employment, supplier deliveries, and inventories. A reading above 50% indicates expansion, while a reading below 50% indicates contraction.

The ISM report also shows that the demand, consumption, and inputs of the manufacturing sector are growing at a faster pace, despite the challenges of labor and supply chain disruptions. The New Orders Index registered 64.8%, up 3.7 percentage points from January, indicating strong demand across all industries. The Production Index registered 63.2%, up 2.5 percentage points from January, reflecting a robust increase in output. The Employment Index registered 54.4%, up 1.8 percentage points from January, indicating a return to job growth after a one-month contraction. The Supplier Deliveries Index registered 72%, up 3.8 percentage points from January, indicating slower deliveries due to supply chain difficulties. The Inventories Index registered 49.7%, up 3.6 percentage points from January, indicating a slight contraction in raw materials inventories.

The metal forming industry is well-positioned to capitalize on the growing demand and opportunities in the manufacturing sector, as it offers a variety of advantages such as high strength-to-weight ratio, design flexibility, cost-effectiveness, and environmental sustainability. Metal forming processes, such as stamping, forging, extrusion, and hydroforming, can produce complex and precise shapes with minimal material waste and energy consumption, making them ideal for lightweight and high-performance applications.

However, the metal forming industry also faces some challenges and uncertainties that could affect its growth and profitability. Some of the key challenges include:

  • Rising costs of raw materials, such as steel and aluminum, due to tariffs, trade wars, and supply chain disruptions.
  • Shortage of skilled labor and talent, as the aging workforce retires and the younger generation shows less interest in manufacturing careers.
  • Rapid technological changes and innovations, such as automation, digitalization, and additive manufacturing, that require constant adaptation and investment.
  • Increasing competition from low-cost manufacturing countries, such as China and India, that offer lower labor and production costs.
  • Stringent environmental and safety regulations, such as emissions standards and workplace safety rules, that impose additional costs and compliance requirements.

To overcome these challenges and maintain their competitive edge, metal formers need to adopt proactive and strategic approaches, such as:

  • Diversifying their product portfolio and customer base, by exploring new markets and applications, such as electric vehicles, renewable energy, and medical devices.
  • Investing in research and development, by collaborating with academic and industry partners, to develop new materials, processes, and products that meet the evolving customer needs and expectations.
  • Leveraging digital technologies, such as artificial intelligence, cloud computing, and data analytics, to enhance their operational efficiency, quality control, and customer service.
  • Embracing sustainability, by implementing green practices, such as reducing waste, recycling materials, and using renewable energy sources, to improve their environmental performance and social responsibility.
  • Developing their human capital, by attracting, retaining, and training their workforce, to foster a culture of innovation, collaboration, and excellence.

The metal forming industry is a vital and dynamic sector of the manufacturing economy, that has shown remarkable resilience and optimism in the face of the COVID-19 pandemic. By capitalizing on the opportunities and addressing the challenges, metal formers can achieve sustainable growth and profitability in the future.

28. February 2024 by Jack
Categories: News | Leave a comment

Bending Large Radii on the Press Brake: Challenges and Solutions

Bending large radii on the press brake is a common task in metal fabrication, especially for applications that require smooth curves and minimal distortion. However, forming large-radius bends also poses some challenges, such as excessive springback and multi-breakage. In this article, we will explain what these challenges are, why they occur, and how they can be overcome with proper tooling and techniques.

What is Springback and Why Does it Happen?

Springback is the tendency of the metal to return to its original shape after bending. It is caused by the elastic recovery of the material, which means that some of the deformation is not permanent. Springback is influenced by several factors, such as the material type, thickness, grain direction, bend angle, bend radius, and tooling geometry.

Springback is more pronounced for large-radius bends, because the material undergoes less plastic deformation and more elastic deformation. This means that a larger portion of the bend is reversible, and the final angle and radius are different from the intended values. Springback can affect the accuracy and consistency of the parts, as well as the fit and function of the assembly.

How to Reduce Springback for Large-Radius Bends?

One way to reduce springback for large-radius bends is to use a springback calculator, which can provide a ballpark estimate of the final angle and radius based on the material properties and the tooling parameters. A springback calculator can help to adjust the punch and die angles to compensate for the expected springback. However, a springback calculator is not a substitute for trial and error, as there may be variations in the material and the machine performance.

Another way to reduce springback for large-radius bends is to use a large-radius punch insert, which is a tool that has a radius larger than the standard punch radius. A large-radius punch insert can create a smoother bend with less stress and strain on the material, resulting in less springback. There are different sizes of large-radius punch inserts available, ranging from 0.25 in. to 4 in. The choice of the large-radius punch insert depends on the desired bend radius and the material thickness.

What is Multi-Breakage and Why Does it Happen?

Multi-breakage is a phenomenon that occurs when the material lifts away from the punch during the bend. This results in a smaller final bend radius than the punch radius in the center of the bend. Multi-breakage is more likely to happen for large-radius bends, because the material has more room to move and flex under the bending force. Multi-breakage can affect the quality and appearance of the parts, as well as the repeatability of the process.

How to Prevent Multi-Breakage for Large-Radius Bends?

One solution to prevent multi-breakage for large-radius bends is to use a urethane pad or a urethane die, which can provide counter pressure to keep the material in contact with the punch during the bend. A urethane pad or a urethane die acts as a solid hydraulic and forces the material to conform to the punch shape, resulting in a consistent bend radius. Urethane pads and dies are available in different shapes and sizes, and they can be used with standard or large-radius punch inserts.

Another solution to prevent multi-breakage for large-radius bends is to use a flat-tip punch, which is a tool that has a flat surface at the tip of the punch. A flat-tip punch can create a large contact area between the punch and the material, reducing the tendency of the material to lift and break. A flat-tip punch can also reduce the friction and the wear on the tooling, extending the tool life. Flat-tip punches can be used with standard or large-radius dies.

28. February 2024 by Jack
Categories: Fabrication | Leave a comment

How AI Can Streamline the Quote Setup Process for Manufacturers

Manufacturing is a competitive and dynamic industry that requires constant innovation and adaptation. One of the key challenges that manufacturers face is how to handle the increasing number of requests for quotes (RFQs) from customers and suppliers. RFQs are essential for securing new business and maintaining existing relationships, but they also involve a lot of tedious and time-consuming tasks, such as:

  • Receiving the RFQ via email or from a supplier portal
  • Logging the RFQ in a project-tracking spreadsheet
  • Downloading files to the estimator’s hard drive
  • Organizing them into line items on a shared drive
  • Printing out files for markup and review
  • Building out the bill of materials (BOM) in spreadsheets or ERPs

These tasks can take hours or even days to complete, depending on the complexity and volume of the RFQs. They also introduce the risk of human error, inconsistency, and miscommunication, which can lead to inaccurate quotes, lost opportunities, and dissatisfied customers.

Fortunately, there is a solution that can simplify, automate, and secure the quote setup process, cutting quote setup time by 90%: artificial intelligence (AI).

What is AI and how does it work?

AI is a branch of computer science that aims to create machines or systems that can perform tasks that normally require human intelligence, such as reasoning, learning, and problem-solving. AI can be applied to various domains and industries, such as healthcare, education, finance, and manufacturing.

AI works by using algorithms and data to learn from patterns and make predictions, recommendations, or decisions. For example, AI can analyze images, text, speech, or other types of data and extract useful information, such as faces, objects, sentiments, or keywords. AI can also generate new data, such as images, text, speech, or music, based on existing data or rules.

One of the most common and powerful types of AI is machine learning, which is the process of teaching machines to learn from data without explicitly programming them. Machine learning can be further divided into subtypes, such as supervised learning, unsupervised learning, and reinforcement learning, depending on the type and amount of feedback or guidance that the machine receives.

Another important type of AI is natural language processing (NLP), which is the ability of machines to understand and generate natural language, such as English, Chinese, or French. NLP can be used for various tasks, such as translation, summarization, sentiment analysis, question answering, and conversational agents.

How can AI help with the quote setup process?

AI can help with the quote setup process by automating and optimizing the tasks that are repetitive, error-prone, and low-value, such as:

  • Forwarding an RFQ from the email inbox to a quoting platform with all quote files attached
  • Reviewing RFQ emails and associated files for part information, such as quantity, material, tolerance, and finish
  • Building line items and auto-assigning files to line items
  • Storing and organizing all files related to a quote, such as emails, part files, and vendor quotes
  • Pulling data off prints and into a quote by offering data entry fields side by side with prints on one screen

By using AI, manufacturers can reduce the quote setup time from hours or days to minutes or seconds, allowing them to quote faster, reduce mistakes, and win more business. AI can also provide insights and suggestions to improve the quote accuracy and profitability, such as:

  • Comparing quotes with historical data and industry benchmarks
  • Identifying the best pricing strategy and margin for each quote
  • Recommending the optimal manufacturing process and equipment for each part
  • Detecting and flagging potential errors or issues in the quote

What are some examples of AI-supported quote setup software?

One of the leading quoting and collaboration platforms for job shops and contract manufacturers that uses AI to streamline the quote setup process is Paperless Parts. Paperless Parts recently launched its new AI-supported quote setup workflow, which is designed to handle the increase of RFQs and help manufacturers win their share of the half a trillion dollars of manufacturing that is expected to return to the U.S. over the next six years.

Paperless Parts’ quote setup workflow allows users to:

  • Forward an RFQ from their email inbox to Paperless Parts to start a quote with all quote files attached
  • Use AI to review RFQ emails and associated files for part information, build line items, and auto-assign files to line items
  • Have a designated area for storing and organizing all files related to a quote, such as emails, part files, and vendor quotes
  • Copy and paste directly from an email or CSV or manually manipulate line items, assemblies, and supporting files with drag-and-drop functionality
  • Use the platform’s PDF viewer to pull data off prints and into a quote by offering data entry fields side by side with prints on one screen

Paperless Parts also offers other features and integrations that enhance the quoting and collaboration experience for manufacturers, such as:

  • TechMate™, a tool that automatically generates 3D models from 2D prints
  • PEMConnect™, a tool that automatically identifies and prices PEM® fasteners
  • Marketing solutions for job shops, such as website design, SEO, and lead generation
  • Implementation and onboarding services, such as data migration, training, and support
  • Security and compliance features, such as encryption, backups, and CMMC readiness

Another example of AI-supported quote setup software is QuoteMachine, a cloud-based platform that helps manufacturers create and send professional quotes and proposals. QuoteMachine uses AI to:

  • Extract data from CAD files and generate instant quotes
  • Analyze customer behavior and preferences and provide insights and recommendations
  • Automate follow-ups and reminders and track quote status and performance

QuoteMachine also integrates with various tools and platforms, such as:

  • CRM systems, such as Salesforce, HubSpot, and Zoho
  • Accounting systems, such as QuickBooks, Xero, and FreshBooks
  • Payment systems, such as Stripe, PayPal, and Square
  • CAD systems, such as SolidWorks, Fusion 360, and Onshape

What are the benefits of using AI-supported quote setup software?

Using AI-supported quote setup software can bring many benefits to manufacturers, such as:

  • Saving time and resources by automating and optimizing the quote setup process
  • Increasing quote accuracy and profitability by using data and insights
  • Improving customer satisfaction and loyalty by providing faster and better quotes
  • Enhancing competitive advantage and market share by winning more business
  • Enabling innovation and growth by focusing on high-value activities

How to get started with AI-supported quote setup software?

Getting started with AI-supported quote setup software is easy and affordable. Manufacturers can choose from various options and plans that suit their needs and budget. For example, Paperless Parts offers a free trial and a flexible pricing model based on the number of quotes per month. QuoteMachine offers a free plan for up to 10 quotes per month and a premium plan for unlimited quotes.

Manufacturers can also request a demo or a consultation from the software providers to learn more about the features and benefits of their platforms. They can also access various resources and tools, such as case studies, customer reviews, product updates, documentation, and webinars, to get the most out of their software.

27. February 2024 by Jack
Categories: Fabrication | Leave a comment

Safety Tips for Laser and Plasma Cutting

Laser and plasma cutting are two of the most widely used technologies for cutting metal and other materials. Both methods offer high precision, speed, and efficiency, but they also pose significant safety hazards for operators and the environment. This article will provide some safety tips and best practices for laser and plasma cutting, as well as a comparison table of their advantages and disadvantages.

What are Laser and Plasma Cutting?

Laser cutting employs a high-powered laser beam, focused through optics, to melt, burn, or vaporize material. The laser beam can be either continuous or pulsed, depending on the application and the material. Laser cutting can cut through various materials, such as steel, aluminum, copper, brass, wood, plastic, and more. Laser cutting is suitable for complex and intricate shapes, as well as thin and delicate materials.

Plasma cutting, on the other hand, uses a plasma torch that creates a high-velocity jet of ionized gas to cut through electrically conductive metals. The plasma is generated by passing an electric current through a gas, such as air, nitrogen, oxygen, or argon. Plasma cutting can cut through thick and hard metals, such as stainless steel, carbon steel, cast iron, and more. Plasma cutting is suitable for simple and straight cuts, as well as thick and tough materials.

Safety Hazards of Laser and Plasma Cutting

Both laser and plasma cutting involve high temperatures, high voltages, and high pressures, which can cause serious injuries and damages if not handled properly. Some of the common safety hazards of laser and plasma cutting are:

  • Electrical shock: Laser and plasma cutting machines require high levels of electricity, which can electrocute operators or cause fires if there is a short circuit, a power surge, or a faulty connection. Operators must ensure that the electrical supply, including amperages, fuses, and breakers, is adequate for their equipment’s demands. They must also wear insulated gloves and shoes, and avoid touching any live wires or metal parts.
  • Fire and explosion: Laser and plasma cutting generate sparks, flames, and molten metal, which can ignite combustible materials, such as oils, greases, paper, wood, or flammable gases. Operators must maintain a safe distance of at least 35 ft. from combustibles, flammables, oils, and greases. They must also have fire extinguishers readily accessible, and equip their machines with flashback protection to prevent gas backflow. They must also avoid cutting materials that contain explosive or toxic substances, such as batteries, aerosol cans, or asbestos.
  • Fumes and dust: Laser and plasma cutting produce harmful fumes and dust, which can irritate the eyes, nose, throat, and lungs, or cause acute and chronic respiratory illnesses. Some of the hazardous substances that can be released during cutting include carbon monoxide, nitrogen oxides, ozone, metal oxides, and hexavalent chromium. Operators must use proper ventilation and exhaust systems to remove the fumes and dust from the cutting area. They must also wear appropriate respiratory protection, such as masks, filters, or respirators, depending on the type and concentration of the contaminants.
  • Eye and skin damage: Laser and plasma cutting emit intense light and radiation, which can damage the eyes and skin, or cause permanent blindness or cancer. The level of exposure depends on the wavelength, power, duration, and distance of the light source. Operators must wear eye protection, such as welding hoods, goggles, or glasses, with the appropriate shade level, typically a level 10 or 11 or greater, to protect their eyes from the visible and invisible light. They must also wear skin protection, such as gloves, jackets, aprons, or sleeves, to protect their skin from the heat, sparks, and UV rays.

Safety Tips and Best Practices for Laser and Plasma Cutting

To ensure the safety of operators and the environment, laser and plasma cutting operations should follow some safety tips and best practices, such as:

  • Workplace hazard assessment: Conducting a thorough workplace hazard assessment is essential for identifying and eliminating the potential risks and hazards of laser and plasma cutting. This assessment should include checking the environmental and operating permits, the electrical and gas supply hoses, the fire prevention and management measures, the PPE selection and availability, and the emergency response plan.
  • Training: Comprehensive training programs are crucial for all operators, especially new or inexperienced ones, to learn the proper operation, maintenance, and troubleshooting of the laser and plasma cutting machines. They should also be familiar with the safety rules and regulations, the hazard communication and labeling, the MSDS sheets, and the first aid procedures.
  • Heightened awareness: Encouraging a culture of safety first, where every operator is aware of the potential hazards and knows how to mitigate them, is essential. Operators should always inspect the machines and the materials before cutting, follow the manufacturer’s instructions and recommendations, use the correct settings and parameters, and report any problems or incidents immediately.

27. February 2024 by Jack
Categories: Fabrication | Leave a comment

How Poor Material Quality Affects Metal Fabrication and How to Avoid It

Metal fabrication is the process of transforming raw metal materials into various shapes and forms for different applications. It involves cutting, bending, welding, assembling, and finishing metal parts using various tools and machines. Metal fabrication is widely used in various industries, such as construction, automotive, aerospace, defense, and more.

However, metal fabrication faces a major challenge that can compromise its efficiency and quality: poor material quality. Poor material quality refers to the condition of the metal sheets or plates that are used for fabrication, which may have defects, impurities, inconsistencies, or other problems that affect their performance and suitability for fabrication.

Poor material quality can cause various issues during metal fabrication, such as:

  • Bending cracking: This occurs when the metal sheet or plate has burrs, cracks, or stress concentrations at the edges, which can cause the material to crack or break when bent.
  • Bending interference: This occurs when the metal sheet or plate has a complex shape or size that collides with the die or the machine during bending, preventing normal formation.
  • Cutting issues: This occurs when the metal sheet or plate has uneven thickness, hardness, or surface quality, which can affect the cutting speed, accuracy, and quality.
  • Welding issues: This occurs when the metal sheet or plate has impurities, contaminants, or different compositions, which can affect the welding strength, appearance, and durability.
  • Finishing issues: This occurs when the metal sheet or plate has scratches, dents, or marks, which can affect the final appearance and quality of the fabricated part.

The table below summarizes some of the common causes and effects of poor material quality in metal fabrication.

Cause Effect
Burrs or cracks at the edges Bending cracking, cutting issues, welding issues, finishing issues
Rolling direction of the sheet Bending cracking, bending interference, cutting issues
Excessively small bending radius Bending cracking, bending interference
Uneven thickness or hardness Cutting issues, welding issues, finishing issues
Impurities or contaminants Welding issues, finishing issues
Different compositions Welding issues, finishing issues
Scratches, dents, or marks Finishing issues

Poor material quality can have serious consequences for metal fabrication, such as:

  • Reduced productivity: Poor material quality can slow down the fabrication process, increase the scrap rate, and require more rework or repair.
  • Increased costs: Poor material quality can increase the material costs, labor costs, energy costs, and maintenance costs of the fabrication process.
  • Lowered quality: Poor material quality can affect the dimensional accuracy, structural integrity, aesthetic appeal, and functionality of the fabricated part.
  • Damaged reputation: Poor material quality can lead to customer dissatisfaction, complaints, returns, or lawsuits, which can damage the reputation and credibility of the fabricator.

Therefore, it is essential to avoid poor material quality in metal fabrication and ensure that the materials used are of high quality and suitable for the fabrication process. Some of the ways to achieve this are:

  • Selecting the right material: The material should match the specifications, standards, and requirements of the fabrication process and the final product. The material should also be compatible with the fabrication methods, tools, and machines used.
  • Inspecting the material: The material should be inspected before, during, and after the fabrication process to check for any defects, impurities, inconsistencies, or other problems that may affect the fabrication quality. The inspection methods may include visual inspection, dimensional inspection, mechanical testing, chemical testing, or non-destructive testing.
  • Handling and storing the material: The material should be handled and stored properly to prevent any damage, contamination, or deterioration that may affect the fabrication quality. The material should be protected from moisture, dust, corrosion, or other environmental factors that may harm the material.
  • Maintaining the equipment: The equipment used for fabrication should be maintained regularly to ensure its optimal performance and quality. The equipment should be cleaned, lubricated, calibrated, and adjusted to prevent any malfunctions, errors, or accidents that may affect the fabrication quality.

27. February 2024 by Jack
Categories: Fabrication | Leave a comment

How a Startup Error Led to a Fire that Injured 23 Workers at a Texas Chemical Plant

The U.S. Chemical Safety and Hazard Investigation Board (CSB) released its final investigation report and incident animation for the 2018 fire that injured 23 workers at the Kuraray America, Inc. EVAL plant in Pasadena, Texas. The report identifies 17 safety issues that contributed to the incident and provides 12 recommendations to prevent similar incidents in the future.

What happened?

The incident occurred on May 19, 2018, during the startup of a chemical reactor system following a scheduled maintenance shutdown – also referred to as a turnaround. High pressure conditions developed inside the reactor and activated the reactor’s emergency pressure relief system, discharging flammable ethylene vapor through piping into an area where a number of contractors were working. Over 2,300 pounds of ethylene were released in approximately three minutes. The work being done by the nearby contractors included welding, which most likely ignited the flammable vapor. Among the 23 workers injured during the incident, two were life-flighted from the facility, one of whom remained in critical condition for several days because of burn injuries. As many as 19 others were transported to the hospital by emergency responders for various injuries.

What caused the incident?

The CSB determined that the cause of the incident was Kuraray’s emergency pressure relief system design that discharged flammable ethylene vapor from the reactor through horizontally aimed piping into the air in an area near workers. If Kuraray’s emergency pressure relief system had been designed to discharge the vapor to a safe location, the flammable ethylene gas should not have harmed any workers.

CSB Chairperson Steve Owens said, “Kuraray could have prevented the injuries to these workers by ensuring that the flammable ethylene gas discharged from its system was directed to a safe location. Kuraray also should have evacuated these workers from the area when the reactor’s high-pressure alarm sounded, since it was signaling a serious problem with the reactor.”

The CSB’s investigation report details a chain of process safety management failures that led to the build-up of excessive pressure inside the reactor. The emergency pressure relief system discharge design is just one of the 17 safety issues identified by the CSB in the report. The additional 16 safety issues are:

Safety Issue Description
Presence of Nonessential Workers During Startup and Upset Conditions Kuraray did not have a policy or procedure to ensure that only essential personnel were present in the process area during startup and upset conditions.
Hazardous Location Recognized and Generally Accepted Good Engineering Practices Kuraray did not follow recognized and generally accepted good engineering practices (RAGAGEP) for hazardous locations, such as the National Electrical Code (NEC), which requires electrical equipment to be suitable for the location and to prevent ignition of flammable vapors.
Process Hazards Analysis Safeguards Kuraray did not identify or implement adequate safeguards to prevent or mitigate the consequences of a flammable vapor release from the emergency pressure relief system.
Process Hazard Analysis Recommendations Kuraray did not adequately address or implement the recommendations from its process hazard analysis (PHA), such as installing rupture disks on the emergency pressure relief system or relocating the emergency pressure relief system discharge piping.
Warning Signs Kuraray did not post warning signs or barricades to alert workers of the potential hazards of the emergency pressure relief system discharge piping.
Equipment Design Kuraray did not design the emergency pressure relief system discharge piping to minimize the potential for flammable vapor accumulation or ignition.
Operating Procedures Kuraray did not have clear, accurate, and consistent operating procedures for the startup of the reactor system.
Operator Training Kuraray did not provide adequate operator training on the startup of the reactor system, the emergency pressure relief system, and the response to abnormal operating conditions.
Abnormal Operating Conditions Kuraray did not have a formal process to identify, evaluate, and manage abnormal operating conditions, such as high pressure in the reactor.
Safety Interlock Disabling Kuraray did not have a policy or procedure to control the disabling of safety interlocks, such as the high-pressure trip on the reactor.
Alarm Management Kuraray did not have an effective alarm management system to ensure that critical alarms, such as the high-pressure alarm on the reactor, were properly configured, prioritized, and responded to.
Process Alarm Response Kuraray did not have a clear and consistent process alarm response procedure or training for operators.
Safe Operating Limits Kuraray did not establish or communicate safe operating limits for the reactor system, such as the maximum allowable pressure.
Environmental Permit Limits Kuraray did not comply with its environmental permit limits for the emergency pressure relief system, which required the use of a flare to combust the flammable vapors.
Safety Management System Self-Assessment Audits Kuraray did not conduct effective safety management system self-assessment audits to identify and correct gaps in its process safety performance.

What can be done to prevent similar incidents?

The CSB issued 12 recommendations to Kuraray America to address the safety issues identified in the report. The recommendations include:

  • Developing an emergency pressure relief system design standard to ensure discharge to safe locations
  • Developing and implementing a policy and procedure to ensure that only essential personnel are present in the process area during startup and upset conditions
  • Following RAGAGEP for hazardous locations, such as the NEC
  • Conducting a comprehensive PHA of the emergency pressure relief system and implementing the recommendations
  • Posting warning signs or barricades to alert workers of the potential hazards of the emergency pressure relief system discharge piping
  • Reviewing and revising the operating procedures for the startup of the reactor system
  • Providing adequate operator training on the startup of the reactor system, the emergency pressure relief system, and the response to abnormal operating conditions
  • Developing and implementing a formal process to identify, evaluate, and manage abnormal operating conditions
  • Developing and implementing a policy and procedure to control the disabling of safety interlocks
  • Developing and implementing an effective alarm management system
  • Establishing and communicating safe operating limits for the reactor system
  • Complying with the environmental permit limits for the emergency pressure relief system

The CSB also issued two recommendations to the American Chemistry Council (ACC) and the American Institute of Chemical Engineers’ Center for Chemical Process Safety (CCPS) to develop and disseminate guidance on emergency pressure relief system design and management.

The CSB is an independent federal agency that investigates major chemical incidents and issues recommendations to improve chemical safety. The CSB’s final report and incident animation for the Kuraray America investigation can be accessed at CSB Releases Final Report and Incident Animation for Kuraray Investigation.

25. February 2024 by Jack
Categories: News | Leave a comment

How Exxon Mobil and Industrial Tech Giants are Leading the Open Process Automation Revolution

What is Open Process Automation?

Open Process Automation (OPA) is a new paradigm for industrial automation that aims to break the barriers of proprietary and legacy systems and enable interoperability, portability, and innovation across different vendors, platforms, and applications. OPA is based on open standards, such as the IEC 61499 standard for distributed control systems, and a vendor-agnostic architecture that allows plug-and-play integration of components and devices from multiple sources. OPA also leverages the latest technologies, such as cloud computing, edge computing, artificial intelligence, and machine learning, to enhance the performance, efficiency, and flexibility of industrial processes.

Why is Exxon Mobil interested in OPA?

Exxon Mobil is one of the world’s largest energy companies, with operations in over 200 countries and territories. The company produces and supplies oil, natural gas, petrochemicals, and other products to meet the global demand for energy. Exxon Mobil is also committed to innovation and sustainability, investing in research and development, new technologies, and low-carbon solutions.

Exxon Mobil sees OPA as a strategic opportunity to transform its industrial automation systems and achieve its business goals. The company believes that OPA can help it improve its operational excellence, reduce its capital and operating costs, increase its agility and scalability, and accelerate its digital transformation. Exxon Mobil also hopes that OPA can enable it to leverage its own intellectual property and expertise in advanced control and optimization, as well as benefit from the innovation and collaboration of the OPA ecosystem.

How is Exxon Mobil collaborating with other industry leaders on OPA?

Exxon Mobil is not only a user, but also a driver and a leader of the OPA movement. The company has been actively involved in the Open Process Automation Forum (OPAF), a consortium of end-users, suppliers, system integrators, standards organizations, and academia, that was established in 2017 to develop and promote the OPA standards and specifications. Exxon Mobil has also partnered with several industry leaders, such as Schneider Electric, Intel, Dell, VMware, and Yokogawa, to conduct field trials and pilot projects of OPA systems in its production facilities.

One of the most notable examples of Exxon Mobil’s collaboration with other industry leaders on OPA is the field trial that was announced in November 2021 at the NAMUR General Assembly, a conference of process automation professionals in Germany. The field trial, which is expected to be engineered and started up during 2022-23, will involve the installation of an OPA system in one of Exxon Mobil’s noncritical production facilities. The OPA system will consist of components and devices from different vendors, such as Schneider Electric’s EcoStruxure Automation Expert, Intel’s processors, Dell’s servers, VMware’s virtualization software, and Yokogawa’s field instruments. The field trial will also leverage the UniversalAutomation.Org (UAO) runtime, an open-source implementation of the IEC 61499 standard, that was donated by Schneider Electric and is managed by an independent association. The field trial will aim to demonstrate the feasibility, functionality, and benefits of OPA, as well as identify and address the technical and commercial challenges and gaps.

What are the benefits and challenges of OPA?

OPA promises to bring many benefits to the industrial automation sector, such as:

  • Increased performance and efficiency: OPA can enable faster and more accurate control and optimization of industrial processes, as well as better utilization of resources and energy.
  • Reduced costs and risks: OPA can lower the capital and operating expenses of industrial automation systems, as well as mitigate the risks of obsolescence, vendor lock-in, and cybersecurity threats.
  • Enhanced flexibility and scalability: OPA can allow for easier and cheaper integration, modification, and expansion of industrial automation systems, as well as support for diverse and dynamic applications and environments.
  • Accelerated innovation and collaboration: OPA can foster a more open and competitive market for industrial automation solutions, as well as stimulate the development and adoption of new technologies and best practices.

However, OPA also faces many challenges and barriers, such as:

  • Technical complexity and uncertainty: OPA involves a high level of technical complexity and uncertainty, as it requires the integration and interoperability of heterogeneous and distributed components and devices, as well as the adoption and implementation of new standards and technologies.
  • Commercial readiness and viability: OPA is still in its early stages of development and deployment, and it lacks the commercial readiness and viability that are needed to convince and attract the end-users and suppliers of industrial automation systems.
  • Cultural and organizational resistance: OPA represents a radical change from the traditional and established ways of doing industrial automation, and it may encounter cultural and organizational resistance from the stakeholders who are used to or benefit from the status quo.

What is the future of OPA?

OPA is a visionary and ambitious initiative that aims to revolutionize the industrial automation sector. However, it is also a complex and challenging endeavor that requires the collaboration and commitment of multiple and diverse actors. The future of OPA depends on the ability and willingness of the end-users, suppliers, system integrators, standards organizations, and academia, to work together and overcome the technical, commercial, and cultural obstacles that stand in the way of OPA’s realization and adoption. Exxon Mobil and other industry leaders are playing a key role in advancing and promoting OPA, but they cannot do it alone. They need the support and participation of the entire industrial automation community, as well as the regulators and policymakers, to make OPA a reality and a success.

23. February 2024 by Jack
Categories: News | Leave a comment

How BASF is Transforming Plastic Waste into New Products in the U.S.

BASF, the world’s largest chemical producer, has announced that it will incorporate chemical recycling into its U.S. manufacturing operations. This innovative process will allow BASF to use plastic waste and end-of-life tires as raw materials for producing new plastics and other products.

What is chemical recycling?

Chemical recycling is a process that converts polymeric waste, such as plastics and rubber, into oil or gas products that can be used as feedstock for the chemical industry. Unlike mechanical recycling, which grinds and washes plastic waste to produce recycled plastic with lower quality and limited applications, chemical recycling breaks down the polymers into their building blocks, which can then be used to produce virgin-grade recycled plastic that can be used in demanding applications, such as food contact.

There are different types of chemical recycling technologies, such as pyrolysis, gasification, hydro-cracking, and depolymerization. BASF’s chemical recycling project, called ChemCycling, uses pyrolysis technology, which heats up the plastic waste without oxygen in a reactor. This produces a liquid product called pyrolysis oil, which can be fed into BASF’s integrated chemical production network (Verbund) and used to produce new products, especially plastics.

What are the benefits of chemical recycling?

Chemical recycling has several benefits for the environment, the economy, and the society. Some of these benefits are:

  • Chemical recycling can divert plastic waste from landfills and incinerators, thereby reducing greenhouse gas emissions and harmful chemicals released into the environment.
  • Chemical recycling can produce high-quality raw materials, thereby decreasing the demand for fossil fuels and other natural resources, and increasing the circularity of plastics.
  • Chemical recycling can complement other plastic recycling options, such as mechanical, dissolution, and organic recycling, and can deal with complex plastic waste streams, such as films or laminates, that are not suitable for mechanical recycling.
  • Chemical recycling can create new jobs and business opportunities, as the sector develops and expands.

What are the challenges and opportunities for chemical recycling?

Chemical recycling is still a developing technology that faces some challenges and opportunities. Some of these are:

  • Regulatory framework: Chemical recycling needs a clear and consistent regulatory framework that recognizes it as a recycling process and provides incentives and support for its development and implementation.
  • Public perception: Chemical recycling needs to raise awareness and acceptance among the public and the stakeholders about its benefits and potential, and to address any concerns or misconceptions about its safety and environmental impact.
  • Market demand: Chemical recycling needs to create a stable and reliable market demand for its products, and to align with the sustainability goals and commitments of the customers and the consumers.
  • Technological innovation: Chemical recycling needs to continue to innovate and improve its technology and processes, and to reduce its costs and environmental footprint.

BASF is committed to advancing chemical recycling and contributing to a more circular economy for plastics. By bringing chemical recycling to the U.S., BASF is demonstrating its leadership and vision in the field of sustainable solutions.

23. February 2024 by Jack
Categories: News | Leave a comment

Radiant Section

Radiant section is a part of a fired heater, which is a device used to heat fluids in various industries such as refining, petrochemical, chemical, etc. The main function of the radiant section is to transfer heat from the combustion of fuels to the process fluid flowing inside the tubes. The heat transfer is mainly by radiation, which means the emission of electromagnetic waves from the hot surfaces of the flame and the refractory walls.

Components of Radiant Section

The main components of the radiant section are:

  • Burners: These are devices that mix fuel and air and ignite them to produce a flame. The burners are usually located at the bottom or the side of the radiant section. The number, type, and arrangement of the burners depend on the design and capacity of the fired heater.
  • Tubes: These are metal pipes that carry the process fluid through the radiant section. The tubes are arranged in rows or coils along the walls and the roof of the radiant section. The tubes are usually made of carbon steel or alloy steel, depending on the temperature and pressure of the process fluid. The tubes have different diameters, thicknesses, and lengths, depending on the heat transfer requirements and the fluid properties.
  • Tube supports: These are structures that hold the tubes in place and prevent them from sagging or buckling due to thermal expansion and contraction. The tube supports are usually made of refractory materials or metal bars. The tube supports can be fixed or sliding, depending on the design and operation of the fired heater.
  • Refractory: This is a material that lines the walls and the roof of the radiant section. The refractory acts as an insulation and a protection for the metal casing of the fired heater. The refractory also reflects some of the heat back to the tubes, enhancing the heat transfer by radiation. The refractory can be made of bricks, castables, or ceramic fibers, depending on the temperature and the service life of the fired heater.

Heat Transfer in Radiant Section

The heat transfer in the radiant section can be divided into three steps:

  • Combustion: This is the process of burning the fuel and air mixture in the burners, producing heat and flue gas. The combustion is controlled by the fuel flow rate, the air flow rate, and the air-fuel ratio. The combustion efficiency is the ratio of the actual heat release to the theoretical heat release of the fuel. The combustion efficiency depends on the type and quality of the fuel, the burner design, and the operating conditions. The combustion efficiency can be improved by optimizing the fuel and air distribution, minimizing the excess air, and reducing the heat losses.
  • Radiation: This is the process of emitting electromagnetic waves from the hot surfaces of the flame and the refractory. The radiation intensity is proportional to the fourth power of the absolute temperature of the surface. The radiation intensity also depends on the emissivity of the surface, which is a measure of how well the surface emits or absorbs radiation. The emissivity ranges from 0 to 1, where 0 means no emission or absorption, and 1 means perfect emission or absorption. The emissivity of the flame and the refractory are usually close to 1, while the emissivity of the tubes are lower, depending on the material and the surface condition. The radiation heat transfer is calculated by using the Stefan-Boltzmann law, which states that the net heat transfer between two surfaces is proportional to the difference of the fourth power of their absolute temperatures and their emissivities. The radiation heat transfer can be enhanced by increasing the temperature and the emissivity of the flame and the refractory, and decreasing the temperature and the emissivity of the tubes.
  • Convection: This is the process of transferring heat by the movement of the flue gas and the process fluid. The convection heat transfer is calculated by using the Newton’s law of cooling, which states that the heat transfer between a surface and a fluid is proportional to the difference of their temperatures and the convection heat transfer coefficient. The convection heat transfer coefficient depends on the fluid properties, the fluid velocity, and the surface geometry. The convection heat transfer can be enhanced by increasing the fluid velocity and the convection heat transfer coefficient.

Example of Radiant Section

The following table shows an example of the radiant section of a fired heater that heats crude oil from 100°C to 350°C. The fired heater has 12 burners, each with a heat release of 10 MW. The radiant section has 120 tubes, each with a diameter of 150 mm, a thickness of 5 mm, and a length of 10 m. The tubes are arranged in 10 rows, with 12 tubes per row. The refractory has a thickness of 200 mm and an emissivity of 0.8. The crude oil has a mass flow rate of 100 kg/s, a specific heat of 2.5 kJ/kg.K, and a density of 800 kg/m3. The flue gas has a temperature of 1200°C, a specific heat of 1.2 kJ/kg.K, and a density of 1.2 kg/m3. The convection heat transfer coefficient of the flue gas is 50 W/m2.K, and the convection heat transfer coefficient of the crude oil is 100 W/m2.K. The emissivity of the tubes is 0.6, and the emissivity of the flame is 1.

Parameter Value Unit
Heat release of burners 120 MW
Heat transfer by radiation 108 MW
Heat transfer by convection 12 MW
Heat absorbed by tubes 108 MW
Heat absorbed by crude oil 100 MW
Heat loss by flue gas 8 MW
Combustion efficiency 83.3 %
Radiation efficiency 90 %
Convection efficiency 10 %
Overall efficiency 75 %
Flame temperature 1200 °C
Effective gas temperature 1000 °C
Tube-wall temperature 500 °C
Refractory temperature 800 °C

15. February 2024 by Jack
Categories: Basic | Leave a comment

Spherical Shell Formula in Process Engineering

A spherical shell is a three-dimensional shape that looks like a hollow ball. It is made up of two concentric spheres, which means they have the same center, but different sizes. The spherical shell is the region between the inner and outer spheres. You can think of it as a ball that has been carved out from a bigger ball.

One example of a spherical shell is a soccer ball. The soccer ball has an inner layer of rubber and an outer layer of leather. The spherical shell is the space between these two layers. Another example is the Earth. The Earth has an inner core, an outer core, a mantle, and a crust. The spherical shell is the space between any two of these layers.

A spherical shell is a hollow sphere, commonly used in various engineering applications due to its uniform stress distribution under internal pressure. The formula for calculating the wall thickness of a spherical shell subjected to internal pressure (P) is given as:

    \[ t = \frac{{P \cdot r}}{{2 \cdot S}} \]

Where:

  • t = wall thickness of the spherical shell
  • P = internal pressure
  • r = radius of the spherical shell
  • S = allowable stress of the material

This formula helps engineers determine the necessary thickness of the shell to ensure it can withstand the pressure without experiencing failure.

Example:

Let’s consider a scenario where a process engineer is tasked with designing a spherical pressure vessel for storing compressed air. The vessel is required to withstand an internal pressure of 500 psi (P) and is made of stainless steel, which has an allowable stress (S) of 20,000 psi. The design specifies a radius (r) of 36 inches.

Calculation:

Using the spherical shell formula, we can calculate the required wall thickness (t):

    \[ t = \frac{{500 \text{ psi} \cdot 36 \text{ inches}}}{{2 \cdot 20,000 \text{ psi}}} \]

    \[ t = \frac{{18,000 \text{ psi-inch}}}{{40,000}} \]

    \[ t = 0.45 \text{ inches} \]

Results:

Based on the calculation, the required wall thickness of the spherical pressure vessel is 0.45 inches. This thickness ensures that the vessel can safely contain the internal pressure of 500 psi without experiencing failure.

14. February 2024 by Jack
Categories: Formula | Leave a comment

← Older posts

Newer posts →