Chemical Processing Minute Clinic

In Chemical Processing's Distilled Podcast, we discuss flaws in operator training, focusing on "time to train." Companies can waste millions of dollars by not optimizing training duration, often using fixed-length programs regardless of trainees' prior experience. Feedback loops to adjust training time based on individual competency and learning objectives are imperative. Indeed, proper assessment could identify struggling trainees and high performers who could be fast-tracked.

This episode from Chemical Processing's Distilled podcast shares industry best practices for chemical plant reliability and maintenance. Key recommendations include understanding equipment failure modes through predictive maintenance techniques like vibration analysis and thermography, developing balanced preventive maintenance programs that avoid over-maintaining equipment, and conducting thorough root cause analysis using methods such as 5-why analysis and fishbone diagrams.

With Easter just behind us and chocolate consumption hitting its second-quarter 2025 peak, it's a good time to reflect on the theological and processing developments that have got us where we are today. In this In Case You Missed It Episode, Chemical Processing's Editor-in-Chief Traci Purdum brings the written word to life, and Seán Ottewell, editor-at-large, provides the story. The original column was posted to the site on May 5, 2025. Chocoholics unite!

Executive Editor Jonathan Katz highlights the news of April 2025. Trump's EPA eases regulations while confusion stalls recycling innovation and Dow delays climate investments.

Olivia followed all the right steps. As a chemical engineer at a major manufacturing plant, she had a mentor – a senior colleague who gave her great advice on career growth, technical skills and workplace challenges. She networked, took on projects and worked hard. Yet, after years of effort, she was still in the same role, watching others get ahead. Then she met Rahul, a senior executive who didn't just advise – he advocated. This In Case You Missed It episode features a column by Lauren Neal, Chemical Processing's Workforce Matters columnist. It is read by Editor-in-Chief Traci Purdum.

This Earth Day, the chemical industry finds itself at a crossroads in an era of deregulation. Growing up in Cleveland, Ohio, you learn early on all the things that put the city on the map. Two local cartoonists, Jerry Siegel and Joe Shuster, gave the world Superman. The city pioneered traffic safety with the world's first electric signal in 1914, forever changing how streets operate. The Rock and Roll Hall of Fame calls Cleveland home, as does the house from "A Christmas Story," where the warning "You'll shoot your eye out" is synonymous with Red Ryder BB guns. And yes, our river caught fire — more than once.

In this episode, Traci and Dave discuss the importance of practice in operator training programs. Practice is often overlooked despite being crucial. Realistic scenarios that mimic real-world conditions, including time constraints and environmental challenges, are beneficial to anchoring lessons learned. Feedback loops are also necessary to evaluate individual performance and improve training programs. The new concept of micro training, in addition to having operators teach others, helps operators continuously practice their skills.

In a recent episode of Ear on Processing from Chemical Processing's sister brand Processing, chief editor, Jesse Osborne, sat down with Greene Tweed's business development manager for life sciences markets. They discussed the importance of sustainability for process manufacturers and outlined how Green Tweed's FFKM products are assisting in that regard.   Enjoy this bonus episode of Distilled.

Trade organizations express concern over rising costs and supply chain disruptions. This episode takes a look at how the Trump administration's whiplash tariffs will impact the chemical industry.

A power shift is underway at the EPA as former American Chemistry Council representatives are positioned to assume key roles under the Trump administration, potentially reshaping the agency's regulatory approach. Meanwhile, safety concerns remain paramount as the U.S. Chemical Safety Board continues investigating a deadly reactor explosion at a Louisville food additive plant that claimed two workers' lives. The CSB has also released new reports analyzing recent industrial accidents to prevent future incidents. In corporate news, major chemical and energy companies including BASF, Chevron, DuPont, and Shell have announced significant executive leadership changes that could influence industry direction in the coming months.

Electromagnetic flow meters are volumetric flow meters that use electromagnetic induction to measure liquid velocity. This measurement method is highly accurate at measuring water-based fluids as they pass through a pipe. They are cost-effective, long-lasting and compatible with existing technology. However, there are things to consider before investing in this technology. Chemical Processing chatted with Joseph Incontri, director of marketing North America at Krohne, to help us understand the pros and cons.

In this episode, Traci and Dave discuss how learning objectives fit into instructional system design. Learning objectives should be measurable, not subject to interpretation, and directly testable. Unlike vague goals like "understand distillation," effective objectives specify demonstrable skills.

I've never seen a piece of equipment that didn't do what it was supposed to. That doesn't mean it did what its user thought it could do. In solids processing, we often struggle with a piece of equipment because it was a poor selection or installed improperly. There are eight specific steps to ensure your equipment choices accurately represent your product and operations. Column "8 Steps for Solids Equipment Selection" by Tom Blackwood and narrated by Traci Purdum.

An Inuit man who was left to his own defenses in the Arctic after being exiled from his family had to fashion a knife out of his own frozen feces…. In this episode, Editor-in-Chief Traci Purdum talks about the Ig Nobels and improbable research that makes you laugh and then makes you think.  

Washington leaders visited the accident site on the two-year anniversary of a train derailment that contaminated air, soil and water. A landmark step toward promoting sound science and advancing U.S. competitiveness has also been taken. LyondellBasell's Houston refinery, in operation for over a century, is closing due to high maintenance costs and shifting market dynamics.  

Job analysis is a crucial component of instructional system design that identifies essential skills and knowledge needed for a job, moving beyond inefficient shadowing methods. However, it's often poorly executed or skipped entirely. Effective analysis should focus on specific behaviors, consider environmental factors, and adapt to technological changes like automation.

"Teamwork matters. Teamwork saves lives." That's the battle cry from Eduardo Salas, the Allyn R. and Gladys M. Cline chair professor in Rice University's psychological sciences department, and Scott Tannenbaum, president at The Group for Organizational Effectiveness Inc. This episode uncovers the ways teams can save lives. The deadly Pemex chemical leak serves as an example.

Work that began in the 1800s is still going strong with the help of a teacher, Motörhead and hypothetical, superheavy elements yet to be discovered.

In this news roundup, Executive Editor Jonathan Katz highlights significant policy shifts, with Trump's energy initiatives reversing environmental protections and renewable energy commitments. Chemical industry regulations face changes with TSCA reform and EPA appointments of former industry executives. Additional developments include expanded PFAS reporting requirements, biofuel research funding and Covestro's U.S. manufacturing expansion.

In this episode of Distilled, CP's Editor Traci Purdum chats with David Strobhar,  founder and principal human factors engineer for Beville Engineering. Dave is also the founder of the Center for Operator Performance. The two discuss Instructional System Design, a systematic training approach developed by the Air Force to create efficient, measurable, and effective training programs across diverse industrial workforces.

In today's episode, Chemical Processing's Editor-in-Chief, Traci Purdum, will be reading this year's Chemical Industry Outlook, written by Martha Gilchrist Moore, chief economist and managing director of the American Chemistry Council, Washington, D.C.  Martha and the ACC have been offering Chemical Processing a glimpse into their economic crystal ball for several years. Here is what's in store for 2025.

Welcome to our first episode of Chemical Processing's Distilled podcast in 2025. This podcast and its transcript can be found at chemicalprocessing.com. I'm Traci Purdum, editor-in-chief of CP. I, like many folks, use the new year to reflect on the past year and find inspiration for the next 365 days during the “Bermuda Triangle” time between the holidays and New Year. You know those days that all mesh together, and you don't know whether it's Tuesday or Saturday, and you've just had a handful of cookies for breakfast? Well, I decided to listen to past episodes of Distilled. I came across many auditory pearls of wisdom, and I whittled them down to four things I plan to work on this year. Maybe you'd like to join me.

In his final news roundup of the year, Executive Editor Jon Katz highlights: Global plastic pollution treaty stalls amid negotiations. DuPont loses lawsuit secrecy bid. EPA closes PFAS chemical review loopholes. Bhopal lessons persist. Chemical facilities warned about winter safety risks.

As a technical expert in a chemical facility, your knowledge is the backbone of operations. However, as your responsibilities increase, transitioning from a purely technical role to one in leadership can be challenging. Developing an inclusive approach not only strengthens team cohesion but also boosts overall performance. Here are five tips for how to evolve from a technical expert into an inclusive leader. Based on a column from Lauren Neal “Technical Expert to Inclusive Leader: How to Evolve Your Leadership Style” Read by Traci Purdum, editor-in-chief, Chemical Processing

Her journey exemplifies professional growth through curiosity, adaptability and seizing unexpected opportunities. Anne Berg, vice president of Manufacturing, Agricultural Solutions Americas at BASF, was recently inducted into the Women in Manufacturing Hall of Fame. Her remarkable 28-year career spans multiple countries and roles. Starting as a process development engineer in Germany in 1996, she has worked in manufacturing leadership positions in Germany, Belgium, Spain, and the United States.

Grab a cup of coffee and spend a few minutes going over the top news in the chemical industry with CP's Executive Editor, Jonathan Katz. Election 2024 Recap: Chemical Industry Sees Regulatory Relief in Trump's Return As manufacturers welcome a potential rollback of Biden-era rules, experts warn companies must still answer to shareholders and customers on environmental commitments.   Trump Selects Zeldin to Lead the EPA Former New York congressman is expected to play a role in industrial deregulation, which could have a major impact on the process industries.   Trump Names Liberty Energy CEO Chris Wright as Next Energy Secretary President-elect selects shale industry leader to head energy department, promising a new era of American energy innovation and global influence.   Chemical Processing Reveals 2024 Job Satisfaction and Salary Survey Results Annual survey continues to highlight a healthy industry outlook among chemical engineering professionals.   CSB Is Like a Dog with a Bone Investigating Safety Cases Chemical Safety Board clears backlog, tackles eight new hazardous incident investigations.  

In the fast-paced world of chemical processing and operations, effective time management is not just a luxury — it's a necessity. Engineers and operators often face complex tasks, tight deadlines and high-stakes environments with an extremely limited margin for error. Implementing effective time-management strategies can significantly enhance productivity, reduce stress and improve overall job satisfaction, but how do you do it?  Written by Lauren Neal, Founder of Valued at Work  Read by Traci Purdum, editor-in-chief Column can be found here.

As manufacturers welcome a potential rollback of Biden-era rules, experts warn companies must still answer to shareholders and customers on environmental commitments. The chemical industry has been yearning for the Trump administration's hands-off approach to regulations ever since Jan. 20, 2021, the day President Joe Biden took office. For chemical manufacturers, the return of Donald J. Trump to the White House symbolizes a momentous shift toward less regulation and bureaucratic oversight.

In Case You Missed It brings the written word to life. In today's episode, I will be reading a column from editor at large Seán Ottewell – “Chemistry History Lesson: From Anti-Plague Elixirs to a Precious Nose That Wasn't.” Danish scientist Tycho Brahe took many of his experiments to his grave. However, researchers from the University of Southern Denmark have found clues that shed light on his mysterious work. Read the column, which was posted on our site Sept. 6, 2024. Read by: Traci Purdum, editor-in-chief Written by: Seán Ottewell

Unlikely allies in sustainability, a fatal chemical leak, an averted dock-worker strike, and BASF's hall-of-famer round out the top stories on reader lists. Executive Editor Jonathan Katz reviews what topped the list for our readers this month.

When it comes to pumping systems, efficiency must be viewed in terms of measurable savings (kilowatts, horsepower) and taken as a whole-system approach. Organizational buy-in and leadership support are crucial. To help us understand how best to achieve efficiency, Chemical Processing chatted with Dr. Gary Dyson, managing director of global engineering at Hydro. Dyson is responsible for thousands of pump designs carried out on upgrades and new equipment.

What truly makes an expert? It's not just about knowing more facts. Discover the 13 key characteristics that set real experts apart, from forming expectancies to mental simulations. Learn how these traits apply across industries and how you can cultivate expertise in yourself and others. Whether you're an operator, manager, or lifelong learner, this discussion on the nature of expertise will change how you think about skill development and decision-making in complex environments.

Chemical Processing's Editor-in-Chief, Traci Purdum, recently sat in on a roundtable of fellow editors and manufacturing alliances to discuss how industry is facing a significant challenge in recruiting both skilled and unskilled workers. Listen in as her fellow business journalists reveal tactics big-name companies are using to attract younger workers to manufacturing careers.

Today's episode highlights Chemical Processing's other podcast series, Process Safety with Trish and Traci. We recently celebrated five years with that brand, and to commemorate that achievement, we hosted a fun show that featured a talented crime writer and well-respected chemical engineer, Fiona Erskine. I like to think about her book series as a glimpse into what James Bond/Nancy Drew would look like as a chemical engineer.

What were the hot topics in September 2024? Executive Editor Jon Katz runs through all the attention-getters. Our monthly roundup of trending stories on ChemicalProcessing.com focuses on what your peers were reading. Executive Editor Jon Katz does his best Walter Cronkite impression as he bring the news to life. If you want to follow along, here are the stories he highlights.

In the second installment of our five-part series on the chemical industry workforce, "Chemical Industry Workforce: Shaping Tomorrow's Talent," Dennis Banks, vice president of Syncrude Maintenance at Suncor Energy Inc., offers his definition of DEI.  “I grew up in a place where there were drive-by shootings — I have bullet holes in my childhood home,” says Dennis Banks, vice president of Syncrude maintenance at Suncor Energy Inc., who grew up in Detroit, went to college in Louisiana and now resides in Fort McMurray, Alberta, Canada. “Some people freeze in the face of chaotic situations. I don't view [many] situations as perilous. So, I'm able to maintain calm and composure in the face of a lot of adversity and chaos because of what I went through growing up.”

Vacuum conveying systems automate the movement of dry materials, offering numerous benefits in industrial processes. They improve safety by controlling dust, reducing spills and handling combustible powders more securely than pressure-conveying systems. These systems enhance quality control through consistent ingredient ratios and efficient packaging, which is crucial for consumer brand management and avoiding costly recalls. However, there are considerations to factor in when selecting a system. To discuss the challenges and benefits of vacuum-conveying, Chemical Processing sat down with David Kennedy, business development manager at VAC-U-MAX. The following is an edited version of that conversation.

Objectively assessing operator knowledge and skills is important. The Center for Operator Performance developed a validated 47-question test on distillation knowledge administered across multiple companies. The test revealed variations in knowledge between companies and individuals, helping identify areas for improvement. The goal is to create more tests on different topics. Key findings include: Simulation-based training correlated with better performance Years of experience didn't necessarily predict test scores The test can be used to benchmark and improve training programs

While watching the movie "Christmas Vacation" for the 67th time, I finally realized that Clark Griswold was a chemical engineer. I leaped down the rabbit hole looking for more famous ChemEs in real life and movies. I found several.

The top trending news stories from August 2024 as reported on ChemicalProcessing.com.   Cheers! Whiskey Waste Becomes Biochemicals A new method to extract valuable bio-based chemicals from whiskey distillery waste streams could be worth up to £90 million ($US 115 million) in global chemical manufacturing markets.   Rice Engineers Design Eco-Friendly Ammonia Reactor New electrochemical process could revolutionize ammonia production, reducing carbon emissions and water pollution   BASF to Produce Bio-Based Ethyl Acrylate, Phasing Out Fossil-Derived Version New product with 40% bio-content from grain sources to launch Q4 2024, reducing carbon footprint by 30% while maintaining specifications.   Get Ready for Our Special Workforce Series CP's upcoming 5-part series will provide insight into the state of the chemical industry workforce.   Deconstructing the Chemical Industry's Skills Gap An aging workforce, fierce competition for graduates and culture clashes: Inside the chemical industry's struggle to fill critical roles.  

Level indicators and pressure applications are crucial in ensuring efficient operations and safety. From basic visual indicators to advanced electronic transmitters, the range of technologies available is vast and constantly evolving.  Chemical Processing chatted with Jason Kuzmiak, Chemical Industry Manager at VEGA Americas, to delve into the world of level measurement and pressure instrumentation, exploring the various solutions, the challenges faced in implementation and the factors that drive customer choices. 

As winter approaches, you should assess how well your plant is protected from problems that frigid conditions can pose. In this episode, Managing Editor Amanda Joshi reads a column from Dirk Willard. If you don't have a mother or spouse nagging you to wear a coat, give this a listen. And don't forget to take out the trash! Original column: Safety: Winterization Goes Beyond Equipment Articles referenced in this podcast: Get Ready for the Next Big Freeze Time to Prepare for Winter Prevent Accidents During Subfreezing Weather Winter Weather Dangers: Why Winterizing is Crucial for Chemical Plants. Winter-proof Your Workplace to Prevent Slips and Falls

Operator roles have expanded beyond valve-turning. Future operators will need broader understanding of chemistry, equipment and instrumentation to effectively troubleshoot and communicate issues. In this podcast we discuss the changing landscape of operator training. Three key factors are driving change: a new generation of workers comfortable with mobile technology, emerging technologies like virtual reality and evolving job expectations.

Here is a look at the three top trending stories as reported on ChemicalProcessing.com. Explosion at Honeywell Plant Occurred Two Years After Replacement Recommendation, CSB Reports --Management approved the project but did not purchase or install a replacement shell before the Jan. 23, 2023, explosion. Dow Reports Power Outage at Freeport Operations Due to Hurricane Beryl -- Company says it's working to restore power to the plant. What Ditching The Chevron Deference Means for the Chemical Industry --TSCA advocates and adversaries must be relentlessly compelling, fact-based and thorough in advocating for their positions in a Chevron-free world.    

In Case You Missed It brings the written word to life. In today's episode, Editor-in-Chief Traci Purdum will be reading an article from Tom Blackwood, Chemical Processing's Solids Advice columnist. This article “Combat Fine Particle Challenges -- What makes them good is also why they're bad” was published to ChemicalProcessing.com July 22, 2024. Here is the full column

Readers ask questions about their motors and our expert responds. Proper troubleshooting is important. Here are a few questions that were posed to our motors expert, Tom Bishop, over the years.  Bishop is a senior technical support specialist with the Electrical Apparatus Service Association (EASA). He joined the EASA staff in 2002 with over 30 years of hands-on engineering experience at electrical machinery manufacturing and apparatus service firms. He has a BS in Electrical Engineering and is a licensed professional engineer. Read by Editor-in-Chief Traci Purdum.

This cognitive bias has operators clinging to beliefs despite contrary evidence. In this episode, we discuss fixation, also known as confirmation bias or tunnel vision. It's a cognitive bias in which people cling to beliefs despite contrary evidence. Dave Strobhar and Traci Purdum discuss how fixation can be problematic in industrial settings, citing examples like the Yom Kippur War and the Three Mile Island incident. Dave offers strategies to combat fixation, including the two-strike rule, testing hypotheses, shift changes, maintaining situational awareness, and fostering open team communication. ChemicalProcessing.com

Focus on clarity in an engineering report. While such reports fall into several types — cost estimates, engineering calculations, proposals and studies (e.g., related to laboratory work or calibration, failures and inspections, or optimization)  — all benefit from a clear discussion and conclusion. Sometimes this requires flexibility to stray from a company's set format. This ICYMI episode revisits a column from contributing editor Dirk Willard. You can read the column here: https://www.chemicalprocessing.com/asset-management/economics/article/11297512/write-engineering-reports-right-chemical-processing Read by Editor-in-Chief Traci Purdum.

Distilled News examines the top three stories trending on chemicalprocessing.com. Hosted by Jonathan Katz, executive editor of Chemical Processing. Safety Lessons from the Great Molasses Flood of 1919 Regulatory Burdens, Barbie and Taylor Swift Impact the Chemical Industry EPA Tightens Grip on Toxic Chemicals, Industry Feels the Heat  

Hackers are targeting manufacturing to leverage intellectual property for big money. In a recent episode of Automation Chat, from Chemical Processing's sister publication The Journal from Rockwell Automation, Teresa Houck, executive editor and host of Automation Chat, digs deep into a study regarding advancing digital transformation in a time of unprecedented cybersecurity risk. If you're not already a subscriber to Automation Chat, you can subscribe to it here: https://rokthejournal.podbean.com/

 Operator training hasn't really changed in the past 50 years, relying heavily on on-the-job training with experienced operators as instructors. However, these operators often lack formal training in teaching methods and techniques. In this episode, we highlight the potential benefits of simulation-based training and the use of dedicated trainers, as well as the advantages of a five-crew rotation system that allows for dedicated training time. We also stress that facilities should focus on sending their trainers to "train the trainer" courses to improve the quality of their training programs and incorporate best practices from other industries, such as aviation and healthcare.