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Engineering a
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CHEMCAD®
CHEMCAD is Chemstations’ integrated suite of intuitive chemical process simulation software that broadens an engineer’s capabilities and increases productivity.
CHEMCAD fits into the chemical engineering work flow and supercharges an engineer’s efficiency when facing the toughest chemical process models or addressing day-to-day challenges.
Engineering advanced. The CHEMCAD® suite of
chemical process simulation software powerfully
advances the chemical engineering thought process
and intuitively adapts to an engineer’s work flow when
simulating chemical, petrochemical, pharmaceutical,
and environmental processes. CHEMCAD is flexible
enough to handle virtually any challenge, yet it operates
within a single graphical user interface. And it’s backed
by the best technical support in the industry.
→
Contents→ Working with CHEMCAD -------------- 1
→ Day-to-Day Engineering Tasks ------- 2
→ Small Projects ---------------------------- 3
→ Large Projects ---------------------------- 4
→ Integrated Solutions -------------------- 5
→ Suite Overview --------------------------- 6
→ Modules, Features, and Unit Operations -------------------------- 8
CHEMCAD has the power and tremendous range of capabilities to meet an engineer’s chemical process simulation needs, from day-to-day challenges to large, multifaceted projects. Its open architecture fits into the chemical engineering computing environment and allows for smooth interaction with other commonly used programs, while its intuitive graphical user interface enables engineers to do their jobs more efficiently and boost productivity.
CHEMCAD is scalable and allows users to purchase only the features they need for a specific industry and process, enabling them to create their own customized version. Each module in the suite can be purchased separately and all modules work together within the same interface, resulting in maximum flexibility and affordability.
CHEMCAD offers numerous benefits that advance the engineering process
and save users both time and money.
→ Has been shown to: › Increase productivity by
an average of 25 percent › Reduce costs by an average
of 30 percent › Improve accuracy of calculations
by up to 80 percent
→ Seamless interaction with integrated products and third-party software, such as Microsoft Excel® and Word®
→ Continually updated in response to industry trends
→ Supports COM/DCOM, OLE, OPC, and CAPE-OPEN, and generates reports in CSV and RTF
→ Built for Intel-based PCs running Microsoft Windows®
→ Requires minimal training
→ User-customizable panes
→ CHEMCAD Explorer pane to make navigating simulations easy
→ Workspace to create and work with process flow diagrams (PFDs)
→ Palette pane for easy drag and drop of unit operations, text, and symbols
→ Message pane makes it easy to see diagnostics as you work with a simulation
→ Toolbar makes common tasks easy to access
→ Graphical plotting of results
→ Tabular reports of results
→ Use tabs to navigate or tile multiple windows
→ 1
Day-to-Day Engineering TasksCHEMCAD helps solve basic calculations and complete daily tasks faster, increasing productivity.
↑ Piping/Valves - Pressure Drop/Line Sizing
↑ Component Family Analyses
Equipment Sizing
Thermophysical Property Calculations
↑ Heat Exchangers
↑ Vessels
↑ Bubble/Dew Points
↑ Data Regression
Pure Components
Binary Interaction Parameters
Small ProjectsCHEMCAD streamlines processes used in smaller projects to improve work flow.
↑ Equipment Design
Distillation with mass transfer calculation
Relief system design/rating with DIERS
Troubleshooting / Process Improvement
↑ Reporting
Equipment/process costing
Process safety analyses
Regulatory compliance reports
Heat and material balance reporting
↑ Model potential customer systems in order to sell equipment and/or processes
← Equipment sizing also available for:
Pumps
Safety Relief Devices
Column Trays and Packing
→ 2
Engineering advanced
→ 3
Large ProjectsMore extensive projects with several team members are made more efficient by CHEMCAD’s integrated modules and intuitive interface.
← Process intensification studies
← Energy efficiency/optimization
← Data reconciliation
← Process economics
← Process development
Fitting reaction kinetics from experimental data
Direct lab experiments and pilot plant runs
Scale up from lab to pilot and pilot to production
← Dynamic simulations
Control system design/checkout
Safety analyses
Integrated SolutionsCHEMCAD can be used as a pivotal player in very large, ongoing projects, working seamlessly with other software programs.
↑ Integrated solutions
Process/plant performance monitoring
Model predictive control
Real-time optimizations
CHEMCAD as the engine for other applications
↑ Microsoft Visual Basic® for Applications
↑ Excel ‘wrappers’ for simulations
↑ Operator training systems
→ 4
Engineering advanced
→ 5
The CHEMCAD suite includes six products that can be purchased individually or bundled as needed to accommodate specific industries, projects, and processes.
CC-STEADY STATEChemical process simulation software that includes libraries of chemical components, thermodynamic methods, and unit operations to allow steady-state simulation of continuous chemical processes from lab scale to full scale.
Ideal for → Users who want to design processes, or rate existing processes, in steady state.
CC-DYNAMICSProcess simulation software that takes steady-state simulations to the next level of fidelity to allow dynamic analysis of flowsheets. The possibilities are endless: operability check-out, PID loop tuning, operator training, even online process control and soft sensor functionality.
Ideal for → Users who want to design or rate dynamic processes.
CC-THERMHeat exchanger design and rating software available as an add-on or standalone program. CC-THERM makes use of multiple international standards for design and materials to make sizing a heat exchanger faster and more accurate. The program covers shell-and-tube, plate-and-frame, air-cooled, and double-pipe exchangers. Rigorous designs are based on CHEMCAD’s foundation of physical property and phase equilibria data.
Ideal for → Users who want to design or vet a design by a vendor of a heat exchanger (single unit at a time), and those who want to rate existing exchangers in new service or perform “what if” calculations.
CC-SAFETY NETPiping and safety relief network simulation software that allows rigorous analysis of any piping network. It combines the latest in two-phase relief device calculation, rigorous pressure drop calculation, rigorous physical property calculation, and rigorous phase equilibrium calculation to deliver fast, accurate answers.
Ideal for → Users who need to design or rate piping networks or safety relief devices/systems.
CC-FLASHPhysical properties and phase equilibria calculation software that is a subset of the CHEMCAD suite (all of the CHEMCAD suite products include CC-FLASH capabilities). This program allows rigorous calculation of physical properties and phase equilibria (VLE, LLE, VLLE) for pure components and mixtures.
Ideal for → Users who need physical property and phase equilibrium data, as well as users who need property prediction and regression.
CC-BATCHBatch distillation simulation software that, when used as an add-on or standalone program, makes batch distillation simulation and design easy with intuitive, operation step-based input. CC-BATCH is extremely flexible, with many operating modes and the capability to model any number of operating steps and conditions. CC-BATCH optimizes batch operation, minimizes intermediate “slop” cuts, and increases productivity.
Ideal for → Users who want to design or rate a batch distillation column.
CHEMCAD has a variety of applications, including:→ Research and Development
→ Project/Process Design
→ Project/Process Redesign and Optimization
→ Operations/Maintenance
→ Safety and Hazard Analysis
→ Environmental Study and Analysis
→ Project and Product Sales
→ Education
CHEMCAD is commonly used in such industries as:→ Exploration and Production
→ Refining
→ Commodity Chemicals
→ Fine and Specialty Chemicals
→ Pharmaceuticals
→ Custom and Toll Manufacturing
→ Engineering and Construction
→ Consulting
→ Process Equipment Manufacturing
→ Power Plants
→ Carbon Capture and Storage
→ Alternative Fuels (Bioethanol, Biodiesel)
→ Academic University Programs
→ 6
Engineering advanced
→ 7
CHEMCAD® modules, features, and unit operationsHere you will find a summary of features and properties of the CHEMCAD suite to allow you to find the modules that satisfy your requirements.
KEY
ALL → ALL MODULES SS → CC-STEADY STATE D → CC-DYNAMICS T → CC-THERM B → CC-BATCH SN → CC-SAFETY NET F → CC-FLASH
FunctionalityALL → Design New Processes
ALL → Model Existing Processes
ALL → Optimize/Debottleneck Existing Processes
ALL → HAZOP Analysis
ALL → Environmental Analysis
ALL → Process Expansion Modeling
SS,D → Economic Feasibility Studies
D,SN → Control System Design/Checkout
D,SN → Advanced Process Control
SS,D • Plant Data Reconciliation
SS,D • Operator Training Systems (OTS)
SS,D • Real Time Optimization (RTO)
SS,D • Process/Plant Performance Monitoring (PPM)
ALL → Day-to-Day Engineering Calculations
SS,D,T,B,SN → Equipment Design/Rating
SS,D,T,B,SN → Process Development
SS,D,T,B,SN → Utility System Design/Checkout
ALL Unit OperationsSS,D → Distillation
SS,D • Shortcut and rigorous
SS,D • Simultaneous correction and rigorous inside out algorithms
SS,D • Three-phase distillation
SS,D • Mass transfer-based distillation for packed and trayed columns
SS,D • Column autoconvergence
SS,D • Reactive distillation
B • Batch distillation
D • Dynamic distillation
SS,D → Reactors
SS,D • Stoichiometric
SS,D • Equilibrium
SS,D • Gibbs free energy minimization
SS,D • Kinetic (PFR or CSTR)
D • Batch (CSTR) Reactor
SS,D → Calculator/Parser
SS,D • User-customizable unit operation
SS,D → Component separator
SS,D,SN → Compressor/Expander (Turbine)
SS,D,SN → Controller (Goal Seeker)
SS,D,SN • Numerical controller similar to solver routine
SS,D,SN → Control Valve
SS,D,SN,F → Divider
SS,D → Excel Unit
SS,D • User-customizable unit operation using a Microsoft Excel spreadsheet as a unit operation
SS,D → Fired Heater
SS,D,SN,F → Flash
SS,D,T,SN → Heat Exchanger
SS,D → LNG Heat Exchanger (multi-stream exchanger)
SS,D → Loop
SS,D • Used to execute a given sequence of UnitOps run until a convergence tolerance is reached
SS,D → Meta
SS,D • Link another flowsheet as a unit operation for nesting large or commonly used simulations
SS,D,SN,F → Mixer
SS,D,SN → Node
SS,D,SN • Allows simultaneous flow and pressure calculations throughout the flowsheet for hydraulic calculations
SS,D → Phase Generator
SS,D,SN → Pipe Simulator
SS,D,SN → PID Controller
SS,D,SN → RAMP Controller
SS,D,SN → Pump
SS → Recorder
SS,D → Stream Reference
SS,D • Transfer process stream information to other stream
SS,D → User-Added Module
SS,D • User-customizable unit operation using a .DLL file created by the user for ultimate customization
SS,D,SN → Valve
SS,D → Vessel
SS,D → Solids Handling:
SS,D • Baghouse Filter
SS,D • Centrifugal Filter
SS,D • Crusher/Grinder
SS,D • Crystallizer
SS,D • Cyclone
SS,D • Dryer
SS,D • Electrostatic Precipitator
SS,D • Hydrocyclone
SS,D • Screen
SS,D • Sedimentator
SS,D • Venturi Scrubber
SS,D • Washer
SS,D → Custom
SS,D • Microsoft Excel spreadsheet unit
SS,D •.DLL generated from C++
SS,D • Visual Basic internal VBA
ALL ThermodynamicsALL → General
ALL • Vapor phase association
ALL • Different K-value models and/or enthalpy models for different units or trays
ALL • Different BIPs for different units or trays
ALL • Vapor-Liquid and Vapor-Liquid-Liquid equilibrium
ALL • Composite heat curve pinch analysis
ALL • Distillation curve assay analysis
ALL • Physical properties databank for pure components (DIPPR)
ALL • BIP database for activity coefficient equations
ALL • Electrolytes database
ALL • Vapor phase association database
ALL • Interface to corporate and/or third-party databases
ALL • Vapor fugacity or Poynting correction
ALL • SRK and Peng-Robinson Alpha function and Boston-Mathias extrapolation option
ALL • Henry components option
ALL • Wilson model salt option
ALL • User-customizable Binary Interaction Parameters
ALL • Binary Interaction Parameters Regression
ALL • Fill in missing BIPs using regression of UNIFAC with one click
ALL → K-values
ALL • Equations of State
ALL - Soave-Redlich-Kwong (SRK)
ALL - Grayson-Streed Modified Chao-Seader
ALL - Peng-Robinson (PR)
ALL - Benedict-Webb-Rubin-Starling (BWRS)
ALL - API Soave-Redlich-Kwong (API SRK)
ALL - Modified Soave-Redlich-Kwong (MSRK)
ALL - Extended Soave-Redlich-Kwong (TSRK)
ALL - Predictive Soave-Redlich-Kwong (PSRK)
ALL - Elliott Suresh Donohoe (ESD)
ALL - Statistical Associating Fluid Theory (SAFT)
ALL - Peng-Robinson-Stryjek-Vara (PRSV)
ALL • Empirical
ALL - ESSO (Maxwell-Bonnell)
ALL - Ideal Vapor Pressure (Ideal Solution)
ALL - Henry’s Gas Law
ALL • Activity Coefficient Methods
ALL - UNIQUAC (UNIQUAC with the new group and surface parameters)
ALL - UNIFAC/UNIQUAC (UNIQUAC with the old group and surface parameters)
ALL - UNIFAC VLE
ALL - UNIFAC LLE
ALL - UPLM (UNIFAC for Polymers)
ALL - Wilson
ALL - T. K. Wilson
ALL - HRNM Modified Wilson
ALL - Van Laar
ALL - Non-Random Two Liquid (NRTL)
ALL - Margules
ALL - GMAC (Chien-Null)
ALL - Scatchard-Hildebrand (Regular Solution)
ALL - Wilson Salt
ALL - Modified UNIFAC (Dortmund)
ALL • Special Systems
ALL - Amines (VLE and LLE) (AMINE)
ALL - Sour Water (SOUR)
ALL - Tri-Ethylene-Glycol/Water Dehydration (TEG Dehydration)
ALL - Flory-Huggins Method for Polymers
ALL - Maurer model for Formaldehyde - Methanol - Water systems
ALL • User Supplied K-values
ALL - Polynomial K-values
ALL - Tabular K-values (USRK)
ALL - Partial Pressures of Aqueous Mixtures (PPAQ) (Tabular Data)
ALL - User Subroutine
ALL - User-Specified Activity Coefficients (ACTX)
SS,D - User Visual C VLE compile program (ADDK)
ALL • Special Option Settings
ALL - Vapor Phase Association
ALL - Hydrocarbon/Water Solubility
ALL - Vapor Fugacity/Poynting Correction
ALL - Salt Effect (Dissolved Salts)
→ 8
Engineering advanced
→ 9
ALL - Ethane/Ethylene, Propane/Propylene special BIPs
ALL - Alpha Function Options
ALL - Solid-Liquid Equilibrium
ALL Predict solid-liquid equilibrium from melting point and heat of fusion
ALL Allows study of solid-liquid and vapor-solid-liquid systems
ALL Model predicts based on assumption of a single solid state
SS,D • CAPE-OPEN imported K-value methods
SS,D • CAPE-OPEN imported thermodynamics
ALL → Enthalpy
ALL • Equations of State
ALL - Redlich-Kwong
ALL - Soave-Redlich-Kwong (SRK)
ALL - Peng-Robinson
ALL - API Soave-Redlich-Kwong (API SRK)
ALL - Lee-Kesler
ALL - Benedict-Webb-Rubin-Starling (BWRS)
ALL - Peng-Robinson-Stryjek-Vara (PRSV)
ALL • Chemical Systems
ALL - Latent Heat
ALL • Special Systems
ALL - Amine
ALL - Steam Table
ALL - Mixed Model
ALL - No Enthalpy (Mass balance only)
ALL • User-Added Data
SS,D - User Visual C VLE compile program (ADDH)
ALL - Polynomial Enthalpy Model (Polynomial H)
ALL - Enthalpy Table
ALL - User Subroutine
ALL • Special Option Settings
ALL - Heat of mixing by gamma
ALL - Heat of solution
ALL - Electrolyte enthalpy
ALL - Ideal gas heat capacity
ALL - Steam tables
ALL - Compressed water pressure correction
SS,D • CAPE-OPEN imported enthalpy
ALL → Transport Properties
ALL • Liquid Density Models
ALL - API Lu’s Method
ALL - Cavett
ALL - Library
ALL - Rackett
ALL • Liquid Density Mixing Rules
ALL - Mole % Weight
ALL - VBA
ALL • Electrolyte Liquid Density Mixing Rules
ALL - Clark Correction to Mole % Weight
ALL - VBA
ALL - Based on Components
ALL - Based on Actual Volume
ALL • Liquid Viscosity Models
ALL - ASME
ALL - Lesou and Stiel
ALL - Library
ALL - Two Term
ALL - Pressure Correction
ALL • Liquid Viscosity Mixing Rules
ALL - Log Average by Mass Fraction
ALL - Log Average by Mole Fraction
ALL - VBA
ALL • Electrolyte Liquid Viscosity Mixing Rules
ALL - Log <> Mass % with Clark Correction
ALL - Log <> Mole % with Clark Correction
ALL • Vapor Density Model
ALL - Chemstations Method
ALL • Vapor Viscosity Models
ALL - Chapman-Enskog
ALL - Library
ALL - Thodos
ALL - Dean-Stiel Pressure Correction
ALL • Liquid Surface Tension Models
ALL - Hakim
ALL - Hydrocarbon Correlation
ALL - Library
ALL - Miller
ALL - Onsager Samaras (Electrolytes)
ALL • Liquid Thermal Conductivity Models
ALL - API Procedure
ALL - Hydrocarbon
ALL - Library
ALL - Riedel/Jamieson (Electrolytes)
ALL • Vapor Thermal Conductivity Models
ALL - API Procedure
ALL - Library
ALL • Vapor Conductivity Correlation (>1 atm)
ALL - No Correction
ALL - API
ALL - Stiel-Thodos
ALL • Custom
SS,D - VBA
SS,D • CAPE-OPEN Imported Transport Properties
ALL → Physical Property Database
ALL • Components
ALL - Over 2,000 pure components from DIPPR
ALL - User-customizable components
ALL Group Contribution Estimation
ALL UNIFAC
ALL Joback
ALL Methyl Esters
ALL Biodiesel
ALL - Edit Components
ALL • Property Regression
ALL → Electrolytes
ALL • Methods
ALL - Pitzer
ALL - mNRTL 1986 and 1982 electrolyte activity methods for strong and weak electrolytes including temperature-dependent interaction parameters
ALL • Binary and ternary interaction parameter database
ALL • Reaction equilibrium database including many common industrial systems; calculated from Gibbs free energy when data is absent
ALL • Expert system assistance for setting up electrolyte chemistry
ALL • True species conversion option
ALL • Electrolyte user database option
ALL • Option to consider electrolyte precipitate formation
ALL FlowsheetingALL → Flowsheet Convergence
SS,T,B,SN,F • Steady State
SS,T,B,SN,F - Sequential modular convergence
SS,T,B,SN,F - Speed up methods (Wegstein, Dominant Eigenvalue)
SS,T,B,SN,F - Simultaneous modular convergence
SS,T,B,SN,F - Flexible flowsheet tolerances
SS,D,SN - Optimization algorithm - maximize or minimize objective function given certain independent variables and constraints
SS,D,SN - Sensitivity and parametric analysis with reporting
SS,D - Data maps to/from Excel
ALL - Unlimited size of flowsheet (unlimited number of streams and unit operations)
ALL - Run entire flowsheet, group of UnitOps, or a single UnitOp
D,SN • Dynamics
D,SN - Full dynamic flowsheeting for operability, training, startup/shutdown
D,SN - Graphical plotting of time-dependent results
D,SN - Online, real-time display of results during calculation
D,SN - Additional mode of operation allowing user interactivity while the simulation is running
D • Operator Training System (OTS)
D CHEMCAD GUI can be disabled and/or hidden for use as an engine in an OTS environment
D Time scale factor for scaling to real time
ALL ToolsSS,D,T,B → Rigorous equipment sizing routines for:
T • Heat Exchangers
T - Shell and Tube
T Design mode - geometry calculated from user constraints and desired performance
T Rating mode - performance calculated from geometry
T Fouling rating mode - fouling calculated from geometry and performance
T Simulation mode - geometry used to calculate performance in a CHEMCAD simulation
T - Double Pipe
T Design mode - geometry calculated from user constraints and desired performance
T Rating mode - performance calculated from geometry
T Fouling rating mode - fouling calculated from geometry and performance
T Simulation mode - geometry used to calculate performance in a CHEMCAD simulation
T Calculation of U-tube or straight tube double-pipe exchangers (sensible-to-sensible heat transfer only)
T Allows multitube arrangements
T - Plate and Frame
T Design mode - geometry calculated from user constraints and desired performance
T Rating mode - performance calculated from geometry
T Fouling rating mode - fouling calculated from geometry and performance
T - Air Cooled
T Design mode - geometry calculated from user constraints and desired performance
→ 10
Engineering advanced
→ 11
T Rating mode - performance calculated from geometry
T Fouling rating mode - fouling calculated from geometry and performance
SS,D,B • Trays (Sieve, Bubble Cap, Valve)
SS,D,B • Packing (Random & Structured)
SS,D,SN • Pipes
SS,D,SN • Pressure Vessels
SS,D,SN • Orifices
SS,D,SN • Control Valves
SS,D,SN • Three-Phase Vessels
SS,D,SN • Safety Relief Devices (DIERS)
SS,D,T,B,SN → Spec (specification) sheets in Microsoft Excel
SS,D,SN → Costing/Economics
ALL → Data Regression
ALL • Pure component physical property regression
ALL • Multicomponent VLE/LLE regression from user data, UNIFAC, or infinite dilution data
ALL • Regression of electrolyte data
SS,D • Reaction rate regression from temperature, heat, and concentration data
SS,D → Data Reconciliation
SS,D,SN,F → Vapor Venting/Depressurizing
ALL → EPA WAR Algorithm for environmental and health impact studies
SS,D,SN,F → Hydrate/Solid CO2 Prediction
SS,D,SN,F → Total Organic Content/Chemical Oxygen Demand Calculation
ALL ReportingALL → Text Reports
ALL • Available in
ALL - Internal text report viewer
ALL - Microsoft® WordPad
ALL - Microsoft Word
ALL - Microsoft Excel
ALL • Stream Compositions/Properties (Single/Multiple Streams or Groups)
ALL • Particle Size Distribution
ALL • Pseudo-Component Curves
ALL • UnitOps (Single/Multiple Unit Operations or Groups)
ALL • Spec Sheets
SS,D,B • Distillation
SS,D,B - Column Profile
SS,D,B - Tray Composition
SS,D,B - Tray Properties
SS,D - Tower Mass Transfer
SS,D,B - Dynamic Column History
SS,D - Column Diagnosis
ALL • Flowsheet Topology
ALL • Flowsheet Thermodynamic Settings
ALL • User Component Data
ALL • Mass and Energy Balance
SS,D,B • Batch Results
D,B,SN • Dynamic Column/Stream/UnitOp Reports
ALL • Full Consolidated Report of Simulation
ALL → Charts
ALL • TPXY
ALL • Binodal
ALL • Residue Curve Maps
ALL • Binodal with Residue Curve Map Overlay
ALL • Binary Liquid-Liquid Equilibrium
ALL • Solid-Liquid Equilibrium
ALL • Stream Properties
ALL • Phase Envelopes
ALL • Composite Curves
ALL • Pseudo-Component Curves
ALL • UnitOp Charts
D,B,SN • Dynamic Charts
ALL • User Specified File chart
ALL • Symbol Builder for Custom Graphic Representations
ALL GUIALL → Explorer Pane
ALL → Unit Operations Palette
ALL → Messaging Window
ALL → Flowsheeting Window
ALL → Help System
ALL → E-mail simulations directly from CHEMCAD (using your e-mail client)
ALL → Autosave system saves data at regular (user-specified) intervals and includes automatic file recovery at startup
SS,D ExtensibilitySS,D → Licensed, embedded Microsoft Visual Basic for
Applications (VBA) and Microsoft Visual Studio® Toolkit for Applications (VSTA) included in CHEMCAD
SS,D → OLE/COM/DCOM
SS,D → CAPE-OPEN Thermo Import
SS,D → OPC Data Server
ALL → XML Export
ALL LicensingALL → 1, 3, & 5 year, monthly, and hourly licenses
available
ALL → SafeNet SuperPro hardware keys (local and network)
ALL → SafeNet License Manager software key (network)
ALL → System Authorization software key (local)
→ 12
Engineering advanced
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To learn more about how CHEMCAD advances engineering, to request a free trial, or to find a distributor in your area, visit chemstations.com or call us at 1.800.CHEMCAD (243 6223) or +1 713.978.7700.
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