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.

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, 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/

 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.

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.

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

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.

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

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.

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

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

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.”

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.

SICK AG's David Inward on Chemical Industry Emissions Monitoring 

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.

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.

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.