Issue 930-31.pdf

december 2018/january 2019 Issue 930/31

The Chemical Engineer NEWS AND VIEWS FROM THE PROCESS INDUSTRIES, BROUGHT TO YOU BY THE INSTITUTION OF CHEMICAL ENGINEERS

BIGGING UP GRAPHENE

The challenges of scaling up production of a wonder material

SAFETY

PROCESS CONTROL

ENGINEERING CAMPAIGN

ICHEME AWARDS

HAZOP-ORTUNITY

DON’T SWITCH OFF

INSIDE OUTREACH

CUE APPLAUSE

PAGE 29

PAGE 38

PAGE 50

PAGE 54

he enefits of eing an early-career scri e

cover930 DG.indd 1

ee ing o erators onsi e with a ance controls

A loo ac at the ear of ngineering

ele rating the winners

06/12/2018 18:01

New year, new special interest group?

IChemE members are now able to access multiple special interest groups free-of-charge. Get more out of your membership in 2019.

Your annual IChemE membership subscription is due on 1 January 2019. Please log into your MyIChemE account to make a payment, update your details and sign up for the special interest groups relevant to you, free-of-charge. IChemE membership is clear evidence of your commitment to professionalism, both in your own professional development and that of others around you. Renew online today www.icheme.org/renewal

tce.930/31.IFC.subsrenewal.indd 1

06/12/2018 16:05

The Chemical Engineer Contents, Issue 930/31 DECember 2018/January 2019

43

54

24

News 3

38 Process automation & Control

Editor’s comment Adam Duckett

calls

for

Howard Boder on stopping operators

schools

from turning off advanced controls

outreach to continue apace into 2019

4

News: in numbers

6

News: in brief

8

News: in depth

43 process automation & control Marty

says

we

should

enabler

Plan for ambitious £22.7bn hydrogen

46 icheme governance

project; UK unveils CCUS action plan;

50

Israels

view cybersecurity as an operations

Andrew Thompson urges members

Execs discuss greener business; How

to become more engaged in IChemE

to reduce cement industry emissions

activities through Congress

16 News: round-up

50 Year of engineering Adam Duckett speaks to engineers,

20 News: R&D

schoolchildren and teachers who took part in 2018 outreach initiatives

Features

54 IChemE awards Amanda Jasi reports the winners of

24 manufacturing

IChemE’s annual awards

Jason Stafford, Omar Matar and Camille Petit discuss the challenges of producing graphene at scale

29 safety Conor Crowley

and colleagues on

the role of HAZOP scribe and what it offers for up-and-coming engineers

32 safety Claude Labrie and Christina Phang on

managing

ALARP

engineering projects

in

major

Regulars 56 59 60 62 63 64

news: icheme letters events and courses Careers products Residue

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 1

contentstofill AD DG.indd 1

06/12/2018 18:10

Short Courses for Professional Development Energy from Biomass Combustion Tuesday 15 – Thursday 17 January 2019 Fluid Bed Processing Wednesday 16 – Friday 18 January 2019 Crystallisation Science and Engineering Wednesday 23 - Friday 25 January 2019

Enhance your CPD online in 2019

Industrial Air Pollution Monitoring Monday 25 - Wednesday 27 February 2019 Gas, Vapour and Dust Explosion Hazards Monday 25 – Friday 29 March 2019 Spray Drying and Atomisation of Formulations Tuesday 2 - Thursday 4 April 2019 To view the full course programmes or to register please visit: www.engineering.leeds.ac.uk/short-courses or contact the CPD team on: T: 0113 343 2494/8104 E: [email protected] @leedsUniCPD

ONLINE To view the full range of courses we offer visit www.icheme.org/online-training

IChemE HAZOP Training An Introduction to HAZOP Discover how HAZOP fits into a wider process safety toolkit. You’ll learn about the technique’s strengths, limitations and when it should be applied, as well as the basics of the process itself.

HAZOP Study for Team Leaders and Team Members Realistic training for team leaders and members. Alongside presentations covering essential aspects of HAZOP, you’ll participate in workshops for continuing processes, sequential operations and computer-controlled plant.

HAZOP Leadership and Management Explores best practice in HAZOP leadership and management. You will learn about the application of the HAZOP technique and how to plan and manage study programmes more effectively. You will also learn how best to lead study teams to ensure maximum effectiveness and successful project execution. Our courses are also available for in-house delivery where content can be customised to meet your specific learning needs. Don’t see what you’re looking for? Contact [email protected] IChe

m

E t

y

re

Safet C

tce HAZOP HP_AD.indd 1

tce.930/31.2.indd 2

www.icheme.org/hazop ISC

en

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 2

06/12/2018 11:08

06/12/2018 12:59

The Chemical Engineer Editor’s comment

Keep the Doors Open adam duckett

A

S the Year of Engineering draws to a close it’s important that the community maintains the momentum into 2019, and of course beyond.

It has been inspiring to experience firsthand the school outreach

events hosted by employers of IChemE members over the past year. The reactions from the children and teachers involved were hugely positive. The key messages being that it’s important that children understand the opportunities available to them, and that it’s more effective if they meet an actual real-life engineer and discover what they do, and why they’re passionate about doing it. The teachers I spoke to said it’s even more valuable if the children get out of school and meet professionals where they work. It helps to open their eyes even further to what working life looks like. Looking back, I’m not sure whether these sort of outreach events were lacking when I was at school in the 90s or that my school simply didn’t have access to, or foster links with, local employers. Either way I can’t help but feel a little short-changed. community make the effort to inspire the next generation, and

I want to echo the common call to arms from those who took part in outreach during the Year of Engineering that more of our community make the effort to inspire the next generation, and that employers throw open their doors and invite schools in. Why limit ourselves to a year?

that employers throw open their doors and invite schools in. Why limit ourselves to a year? The community should commit to using 2018 as a foundation for continued outreach on engineering. Let the momentum build, not dwindle. If you need evidence to share that demonstrates the opportunities available to those who become chemical engineers, please check out a new online series we’ve started running. It proves a nice primer for the outreach you do. To showcase the diversity of

My careers advice at secondary school consisted of meeting with

opportunities, IChemE member Yasmin Ali is talking to a range

some chap for half an hour and being asked what I wanted to do

of fellow chemical engineers to find out what they do, how they

when I grew up. Answer: Premier League footballer, obviously. Not

got there and why they do it. Read and follow the series here:

impossible, but given I hadn’t even made the school team, it seems

https://bit.ly/2PiUKVL

the smarter approach would have been to discuss the subjects I was doing well at/enjoyed, local careers opportunities, the sorts of professions that are calling out for more talent, and the skills that are expected to be in demand soon. And preferably, meet some real-life professionals. These experiences provide mutual benefits. It’s evident from the engineers that I met that these outreach events boost pride in the company and breed confidence. It’s also uplifting to reflect and then

Statements and opinions expressed in The Chemical Engineer

share the value that your work creates for society.

are the responsibility of the editor. Unless described as such,

I want to echo the common call to arms from those who took part in outreach during the Year of Engineering that more of our

they do not represent the views or policies of the Institution of Chemical Engineers.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 3

catalyst930 DG.indd 3

06/12/2018 17:50

News IN NUMBERS

Engineers are the fourth most trusted profession in Britain The Ipsos MORI Veracity Index is a poll which evaluates trust in professions in Britain and has

been running since 1983. The 2018 poll, which

surveyed 1,001 people aged over 15, is the first year that engineering has been an option. The survey found

fourth most trusted profession, behind nurses, doctors, and teachers. 87% of respondents said that they would trust an engineer to tell the truth, rising to 91% for respondents with degree-

that engineers rank as the

level qualifications.

veracity index 2018 – all professions

Inequality in academia The Royal Society of Chemistry has released a report, Breaking the barriers, calling for zero-tolerance over inequality in academia. It gathered data from more than

1,800 people in the chemistry community and found that while barriers such as inflexible working hours apply to both women and men, women are disproportionately affected. When asked if they had seen evidence of the lack of retention and progression of women in academia, either from their own experience or witnessing the experience of others, 99% of women said yes.

78% of respondents who are currently in academia said that the prevalence of short-term contracts has an impact on the retention and

progression of women, and 78% also said that caring responsibilities have an impact. The RSC is launching a new carers’ grant of up to £1,000 to help academics improve their work/family balance.

Nurses Doctors Teachers Engineers Professors Scientists Judges Members of the armed forces The police Television news readers Clergy/priests The ordinary person on the street Civil servants Pollsters Charity chief executives Trade union officials Bankers Local councillors Business leaders Estate agents Journalists Government ministers Politicians generally Advertising executives

96% 92% 89% 87% 86% 85% 83% 78% 76% 62% 62% 62% 62% 52% 48% 45% 41% 40% 34% 30% 26% 22% 19% 16%

% trust to tell the truth

Source: IPSOS MORI

Engineering pay gap Research by SJD Accountancy has revealed that men are paid 25% more than women in the same engineering roles. The firm surveyed over 1,000 contractors to gather data on their salaries, and then compared the salaries of men and women with the same job titles. SJD released an industry pay gap tool on its website, which includes other areas such as oil, where women earn 23% less, gas

where women earn 16% less, energy where

women earn 15% less, and pharmaceuticals where women earn 14% less.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 4

numbers930 DG.indd 4

06/12/2018 15:20

news in numbers

Retracted science papers Retraction Watch has created a searchable database of

18,000 science papers that have been retracted since the 1970s. Around 60% of the retractions were due to scientific misconduct or unethical behaviour, and 40% were due to errors and problems with reproducing the work. An analysis by Science of 10,500 of the papers has

shown that around four of every 1,000 papers are retracted. The number of journals reporting retracted

papers has grown from 44 in 1997 to 488 by 2016.

30,000 authors in the database, 500 account for one quarter of the 10,500 retractions analysed, with 100 of those authors having at least 13 retractions each, and the top 20 authors having more than 30 retractions each. These cases were usually the

Out of

result of misconduct.

Petrochemicals drives growth in world oil demand An International Energy Agency report, The Future of Petrochemicals, has found that petrochemicals will account

third of the growth in world oil demand by 2030, and half the growth in demand by 2050. There will be in an increase of nearly 7m bbl/d of oil, and there will be an additional 83bn m3 of natural gas consumed by 2050. for over a

The chemicals sector emits around 1.5bn which is the equivalent of

tCO2/y,

18% of all industrial-sector

CO2 emissions, or 5% of total combustion-related CO2 emissions.

The report outlines a clean technology scenario, which provides an achievable pathway to decrease air pollutants from chemical production by 90%, decrease water

demand by 30%, and reduce CO2 emissions by nearly

60% by 2050. These emissions savings are made

through alternative feedstocks (6%), plastic recycling

(9%), energy efficiency (25%), coal to natural gas feedstock shifts (25%) and CCUS (35%).

Cumulative direct CO 2 emission reductions in the CTS Alternative feedstocks

6% 9%

Plastic recycling

35%

Energy efficiency

Oil and gas sectors spending on green energy The world’s top 24 oil and gas companies have

Coal to natural gas feedstock shifts

25%

CCUS

25% Source: IEA

collectively spent 1.3% of their 2018 budgets (a total

of US$260bn) on clean energy, according to climatefocussed research provider CDP. The same companies

Increasing investment in energy storage

2017. However, US companies are not investing as

According to BloombergNEF’s annual Long-Term Energy Storage Outlook, the world’s energy storage market is set

invested 0.68% of their budgets between 2010 and much as European companies, with European oil majors

accounting for 70% of the sector’s renewable capacity. Shell intends to spend US$1–2

bn/y on clean energy technologies out of a budget of US$25bn– 30bn and Equinor plans to spend 15–20% of its budget on renewables by 2030.

to attract US$620bn in investment over the next

22 years. Costs in utility-scale lithium-ion battery storage systems are expected to fall 52% between 2018 and 2030. The energy storage market will grow to 942 GW by 2040 and energy storage will contribute 7% to the total installed global power capacity.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 5

numbers930 DG.indd 5

06/12/2018 15:20

NEWS IN BRIEF

The University of Manchester

flexible fellows: Ahu Gümrah Dumanli-Parry and Lisa Joss

The completed facility will be the world’s largest single-train refinery.

Air Products doubles down on gasification AIR Products has agreed to buy General Electric’s gasification business, expanding its syngas business. The acquisition includes GE’s 50% stake in a syngas joint venture with China’s

Shenhua

Coal

to

Liquid

&

Chemical. Formed in 2011, the partnership provides technologies for gasification projects in China. Air Products CEO Seifi Ghasemi said along with the recent purchase of Shell’s gasification business it now has a broad offering to provide syngas for chemicals, fuels, power or refining.

BP launches flexible working fellowships

INEOS buys Ashland composites

BP-FUNDED fellowships at the University of Manchester have been awarded

the composites business from Ashland

to two UK researchers, with the aim of supporting flexible development

Global Holdings, including a butanediol

opportunities. The recipients are chemical engineer Lisa Joss, currently working at

facility in Germany.

Imperial College London, and materials scientist Ahu Gümrah Dumanli-Parry, also

INEOS has announced that it will buy

Ashland produces unsaturated polyester resins, vinyl ester resins, gel

at Imperial. The five-year BP-ICAM Kathleen Lonsdale Research Fellowship provides salaries

coats, and corrosion-resistant fibreglass

and research expenses, as well as additional funds to contribute to a healthy work-

reinforced plastic (FRP). FRP can with-

life balance. This includes the possibility of flexible working, funding for childcare

stand high temperatures and harsh acids,

or caregiving when attending conferences, and claiming funds for special support in

and is becoming an alternative to alloys,

managing disability or health issues.

concrete, and corrosion-prone materials

The new fellowship aims to address some of the ongoing diversity and inclusion

such as stainless steel. The butanediol

issues with academic careers in STEM fields in the UK. A 2016 survey by Nature found

facility in Germany produces intermedi-

that 38% of early-career researchers worked more than 60 hours a week, and 9%

ates for high performance polyesters and

worked more than 80 hours a week. Long hours and uncertain work patterns can be

polyurethanes. The businesses included

difficult for researchers with personal or family commitments, so the new fellowship

in the transaction employ 1,300 people

offers a more flexible approach.

across 20 sites globally. The deal is expected to complete in the first half of 2019.

Dangote refinery halted by heavy rain

operational in 2019 but the company now

FLOODING due to heavy rainfall has

site told Reuters in August that they do

caused damage to the US$10bn Dangote

not expect any gasoline or diesel output

THE thermal oxide reprocessing plant

refinery site in Nigeria.

before early 2022 and even at that stage

(Thorp) at Sellafield, UK, has ceased

they do not expect all the units to be

reprocessing spent nuclear fuel.

The government has been pushing for the 650,000 bbl/d refinery to be

expects production to begin in Q1 2020. However, sources who have been on

complete.

Thorp stops reprocessing

The Thorp facility opened in 1994,

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 6

NIB930 AD DG.indd 6

06/12/2018 13:46

NEWS IN BRIEF

but in 2012 a decision was taken to end

fundamental physical constants, mean-

reprocessing once all remaining con-

ing that all seven base SI units are now

tracts were complete, due to a downturn

defined in a manner that ensures future

in demand.

stability.

Thorp has processed 9,331 t of used

Since 1879, the kilogramme has been

nuclear fuel from 30 customers across

defined by a cylinder of platinum and

nine countries, and the last batch made

iridium, known as the International Pro-

its way through the plant on 9 November.

totype Kilogramme (IPK), but in 1990 it

During

reusable

was discovered it had become lighter by

uranium (96%) and plutonium (1%)

around 50 microgrammes than its offi-

were separated from the high level waste

cial copies.

reprocessing,

the

(3%) and the uranium was then used to

The kilogramme will now be defined using the Planck constant. The uncer-

make more fuel. The storage pool at Thorp will con-

tainty in the kilogramme also impacted

tinue to receive and store spent fuel

the mole, which has been defined in

until the 2070s, and Sellafield is being

relation to the kilogramme since 1971.

reinvented as a centre of expertise for

The mole will now be defined with

nuclear cleanup.

respect to Avogadro’s number. The ampere will be defined with respect to the electric charge carried by a single

Kilogramme, mole, ampere, and kelvin redefined

proton, and the kelvin with respect to the Boltzmann constant. Martin

Milton,

director

at

the

International Bureau of Weights and Measures (BIPM), said the redefini-

Online only Careers in ChemEng In the latest instalment of her series profiling the diversity of career paths open to those who study the subject, IChemE member Yasmin Ali speaks to fellow chemical engineer Rachel Cooke. With a career that started out in chocolate production, and moved on to beer, Cooke now works for Amazon, changing how we shop. https://bit.ly/2AVkItk

Process Hen-gineering Chemical engineer Jimmy Hunter takes us back to 1975 South Africa, to explain how he and his colleagues developed a novel process to turn an

environmental

problem

into

a valuable product. In this case,

Metrologists have voted for new defini-

tion is a landmark moment in scientific

animal feed from calcium hydroxide.

tions of the kilogramme, mole, ampere,

progress.

https://bit.ly/2QK2YLH

“Using the fundamental constants…

and kelvin. The size of the units will not change;

we have a stable foundation from which

they will just be more stable, as they are

to advance our scientific understanding,

Do the Bump (Test)

no longer reliant on physical objects.

develop new technologies and address

Stephen Mellor of Air Products talks

The

some of society’s greatest challenges.”

us through the importance of test-

new

definitions

are

based

on

ing the functionality of portable J.L. Lee/NIST

gas detectors – an essential safety procedure for anyone working in an environment that could contain hazardous gas. Mellor explains how this can be achieved by performing a bump test – a simple method of ensuring portable detectors are working as they should be. https://bit.ly/2EgVkm3

The Power of Listening Listening important

is

probably

skill

we

the

use

in

most our

professional and personal lives. It underpins every face-to-face interaction. Jamie Cleaver discusses how you might get better at it.

weight over: K92, one of the national institute of standards and technology’s platinum-iridium kilogramme masses

https://bit.ly/2PNTw9z

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 7

NIB930 AD DG.indd 7

06/12/2018 13:46

NEWS in depth

it takes two: teesside is one of two sites suggested for a new £8.5bn hydrogen production plant

environment

Engineers publish £22bn blueprint for UK to take lead on hydrogen Project would decarbonise 14% of UK heat by 2034 ENGINEERS have called on the UK

state energy giant and CCS expert

in

government

spend

Equinor. It’s a more ambitious update to

Leeds, Bradford, Halifax, Huddersfield,

£125m (US$159m) designing a hydrogen

the H21 Leeds City Gate project published

Wakefield, Manchester and Liverpool,

production, distribution and storage

in 2016 that established how to convert

representing around 17% of domestic

system that would create the world’s

UK gas networks to carry hydrogen.

gas connections.

to

immediately

largest CO2 reduction project. If realised

The partners suggest the UK builds

it would decarbonise 14% of UK heat by

a 12.15 GW natural-gas-based hydrogen

2034, and all told cost £22.7bn.

Teesside,

Newcastle,

York,

Hull,

production facility that would feed

Climate change challenge

The H21 North of England plan was

hydrogen, in place of natural gas,

The scheme would help the UK meet its

presented at the Institution of Mechani-

through the existing gas distribution

legal obligations to reduce emissions by

cal Engineers in London on 23 November

network to industry and domestic users

80% by 2050 against a 1990 baseline.

by UK gas network operators Cadent and

across the North of England. This would

This would be achieved by converting

Northern Gas Networks, and Norwegian

include converting 3.7m meter points

gas networks to hydrogen between 2028

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 8

NID1H21 DG.indd 8

06/12/2018 16:02

NEWS in depth

team writes, as almost all the methane

and 2034, decarbonising 14% of UK heat

requirements and proven production

by saving 12.5m t/y of CO2.

technologies, the team has recom-

is converted to CO and H2, allowing for

has

mended the UK reforms natural gas into

a high CO2 capture rate, as most of the

focussed primarily on power production

hydrogen using autothermal reforming

CO can be converted to CO2 in the water

with the introduction of renewables,

technology coupled with carbon capture

gas shift reaction. The high temperature

but with gas making up around 40% of

and storage to bury up to 20m t/y of CO2

also allows the reformer to be operated

the UK’s primary energy use, efforts are

offshore in the North Sea. The £8.5bn

at high pressure, which is an advantage

needed on heating if the UK is to achieve

production plant would be sited either in

given that the project’s hydrogen must

its targets.

Easington or Teesside on the east coast

also be delivered at high pressure.

Decarbonisation

of

energy

“The UK still emits 450m t of carbon

of England, where natural gas from the

Asked whether there are any key

per annum,” said Dan Sadler, H21

North Sea is already brought ashore and

engineering challenges for big industry

programme director at Northern Gas

processed, and would consist of nine

to overcome in switching to hydrogen,

Networks. “To meet the Climate Change

1.3

the authors replied that conversion is a

Act target, that needs to be 160m t per

operating in parallel.

GW

autothermal

reformer

units

market issue not a technical one.

annum. So that is a 65% reduction in

“To give you a great example, SABIC

[2017’s] carbon emissions. And that’s

[in Teesside], they have a huge chemical

not only enormous in its own right, it’s actually far bigger than you can perceive because we’ve really picked off the low-hanging fruit…so now we’re into the difficult sectors to decarbonise.”

“The UK still emits 450m t of carbon per annum. To meet the Climate Change Act target, that needs to be 160m t per annum. So that is a 65% reduction in [2017’s] carbon emissions”

works with 17 furnaces, and 135 burners in those furnaces,” Sadler said. “As part of their chemical process they realised they had surplus hydrogen so off their own bat changed the burners so they could go from 0 to 60% blend hydrogen, so again if you’ve got the availability

The H21 concept

The design concept for carbon capture

of the gas, you can develop the burner

Speaking on the fringes of the report’s

involves

technology. It’s not a technical issue, it’s

launch, Equinor project director Henrik

reformer in parallel with the autother-

Solgaard Andersen, told The Chemical

mal reformer. The CO2 is generated at

Engineer: “This technology is based on

high pressure, making it more effi-

proven reference technologies, so all

cient than if released at low pressure

the solutions exist already around the

in a steam reformer fluegas. The ATR

Hydrogen storage and transport

world. The engineering challenge will

is significantly more compact than a

Hydrogen will be produced at a flat rate,

be putting them together; integrating it

traditional SMR but a large oxygen plant

so storage is needed to balance supply

as a complete system.”

will be needed. The high temperature

and demand, and will be especially

in the ATR reactor is an advantage, the

useful to balance out an increasingly

After

studying

national

energy

installing

a

gas-heated

having the bulk availability of the gas”

large mix of intermittent renewables on the grid. The surplus hydrogen would be stored in Yorkshire’s deep salt

H21 North of England project costs table (adapted from report)

caverns which would avoid the need for

capex (£m)

OPEX (£MPA POST 2035 (once conversion and commissioning is complete)

Hydrogen production facility (HPF)

8,520

285

Inter-seasonal hydrogen storage

1,991

63

CO2 transport and storage

1,340

24

Hydrogen transportation system

3,427

3

Appliance conversion

7,500

0

SUB TOTAL

22,778

373

N/A

580 (total annual gas cost is £2,292m based on gas price of £23/MWh)

22,778

955

item

Additional energy cost for hydrogen production facility

TOTAL

re-compression when hydrogen leaves for distribution. The concept provides 8 TWh of inter-seasonal storage, equivalent to installing 62,000 times more storage than provided by the Tesla lithium ion battery recently built in South Australia in response to a series of high-profile power outages. The system would consist of 56 caverns operating at between 85–275 bar along with eight surface facilities. The power required for this inter-seasonal hydrogen storage system would be around 0.073% of the hydrogen supplied. A

new

transportation

system

is

needed to connect the production facility

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 9

NID1H21 DG.indd 9

06/12/2018 16:02

NEWS in depth

and storage system with the existing below 7 bar gas distribution networks. This includes an 80 bar transmission pipeline measuring 520 km long with 23 offtakes, 13 block valves and 50 connection tees; a local hydrogen transmission system operating at a maximum 40 bar pressure and consisting of 334 km of pipelines to distribute hydrogen to strategic points across urban centres; and finally a hydrogen intermediate pressure system comprising 605 km of below 7 bar network mains to allow strategic connections to the existing gas distribution networks. The authors say the number of plumbers and gas engineers required to convert 3.7m meter points between 2028–2035 are well within the UK’s capabilities and the conversion rate is four times lower than when the UK

question time: expert panel answers engineers’ queries at h21 launch event

switched from towns gas in the 1960s and 70s. Estimates are that the conversion would add 7% to the average domestic

gas

bill

in

2035,

onset of the hydrogen economy”.

On top of this, just days before H21 NoE

though

“And like any leader, the first mover

plan was put forth, the government’s

improvements in home efficiencies are

gets the biggest returns and the biggest

Committee on Climate Change published

likely to bring this down.

rewards,” Sadler said. “If you look at

its own study declaring hydrogen a

the Danish with wind turbines – [the]

credible option for decarbonisation but

first mover is still reaping the biggest

warning that its role depends on early

rewards. So, this project has the ability

government commitment and improved

If implemented, the design by default

to not only meet the UK’s 2050 target

support.

will

clusters

in a deliverable system that’s based on

distribution

proven historic reference technology,

network, and bring about the CO2 trans-

but it also has the ability to keep the UK

port and storage infrastructure needed

as the forerunner in this space.”

FEED funding decarbonise

connected

to

industrial

the

gas

and CCS is the only viable way forward. Attention now turns to securing the funding from government for a FEED study. The authors have laid out a detailed FEED delivery programme that includes detailed design, on- and offshore surveying, location screen-

“The obligation

government to

meet

has those

a

legal

[climate]

commitments so it’s not about is it over?

to decarbonise those heavy industry sectors where emissions are unavoidable

If the government fails to commit next year, is the project over?

“this project has the ability to not only meet the UK’s 2050 target in a deliverable system that’s based on proven historic reference technology, but to keep the UK as the forerunner in this space”

But it’s the time pressure,” Sadler said. “You have to get onto it now. You have to take a desk-based detailed report and make it into a real engineering project, so when you want to make your decision, you’re not then waiting four years before you can get one spade in the ground. “The benefits in H21 are undeniable. Creating tens of thousands of

ing, and 3D modelling. All told it will cost £250m and they are confident they

Asked whether the partners have had any

jobs, reusing existing assets, main-

can get private industry to put up half

feedback from government that would

taining choice for customers – gas

of that. They want the government to

indicate interest in helping to fund the

or electric – helping sort air quality

commit to funding the rest by next year.

study, Sadler said “not directly”.

issues with hydrogen vehicles alongside

“£250m seems a lot of money but

“But what I can say is if you look

electric vehicles, leading the world in decarbonisation

strategies

that

are

it’s 1% of the overall project total,” said

at

Sadler, noting that the UK is currently

Strategy, it references 100% hydrogen

entirely transferable – and whilst doing

considered a world leader in “deep

as one of the most credible decarbonisa-

all that meeting your climate change

decarbonisation

tion options.”

obligations.”

thinking…and

the

the

government’s

Clean

Growth

Ad

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 10

NID1H21 DG.indd 10

06/12/2018 16:02

NEWS in depth

environment

UK moving forward with carbon capture, utilisation and storage Minister announces plans for UK CCUS facility operating by 2030s THE

UK

government

has

unveiled

Perry also signed a memorandum of

entirely new industry.”

an action plan for developing carbon

“Without CCUS as part of the solution,

understanding with Norwegian minister

capture, utilisation and storage (CCUS)

reaching our international climate goals

of petroleum and energy Kjell-Børge

projects,

is practically impossible,” said Birol.

Freiberg to collaborate on CCUS projects.

“CCUS can also enhance energy security

Norway is already working on a govern-

The summit was hosted by the UK

and boost economic prosperity. Yet up

ment-backed

government, the International Energy

until now, progress has been muted

CCS project. The agreement provides a

Agency (IEA), and the Global CCS Insti-

and if this continues the challenges we

framework for cooperation in research

tute on 28 and 29 November. It was

face in the energy sector will become

and development, including increased

co-chaired by Claire Perry, the UK

infinitely greater. That is why the IEA

collaboration for knowledge dissemina-

minister for clean energy and growth,

is bringing together industry, govern-

tion, and increased cooperation in areas

and Fatih Birol, executive director of

ments and our own technology network

such regulatory barriers and funding

the International Energy Agency. It was

– as well as the investment community

management.

attended by energy ministers and senior

– to make CCUS a reality.”

at

the

Accelerating

CCUS

summit in Edinburgh.

executives of major energy industries.

The

government

has

full-scale,

full-chain

The conference also coincided with previously

the announcement that the Oil and

attempted to kick-start CCUS in the

Gas Climate Initiative (OGCI) will be

mined all countries are to unlock the

UK,

constructing

potential of this game-changing tech-

2011, and another in 2015, were both

powered full-chain CCUS project at

nology that representatives from across

dropped. Perry announced new plans

Teesside (see p16), and an announce-

the globe are gathered here today in

at the conference for the government

ment from the government that it will

Edinburgh,” said Perry. “The time is

to develop the first CCUS facility by the

invest £175,000 (US$223,500) in Project

now to seize this challenge to tackle

mid-2020s, with the aim of deploying at

Acorn at the St Fergus Gas Terminal in

climate change while kick-starting an

full-scale by the 2030s.

Scotland.

Toby Phillips Photography

“[This summit] shows how deter-

but

a

funding

competition

in

the

world’s

first

gas-

Project Acorn Project Acorn aims to quickly deliver large-scale, cost-effective CO2 transport and storage infrastructure in the Central North Sea. It will take advantage of legacy oil and gas infrastructure to bring the cost down and take advantage of the geological storage sites. The funding for the project will be matched by the Scottish government and the European Commission. Alan James, managing director of Pale Blue Dot Energy and Acorn CCS project leader, said: “Through Acorn

summit: Energy ministers and senior executives of major energy industries at the Accelerating CCUS conference

CCS, Scotland can use legacy oil and gas assets to deliver environmental benefits, unlocking CO2 transportation and storage

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 11

NID2 DG.indd 11

06/12/2018 15:13

NEWS in depth

Toby Phillips Photography

solutions for other carbon capture, utilisation and storage projects along the east coast of the UK. This is a critical and exciting step towards building the UK’s first large-scale CO2 transport and storage infrastructure.” Paul Wheelhouse, Scotland’s minister for energy, connectivity and the islands, said: “Scotland’s key CCUS resource is our vast potential for the storage of CO2. Scotland’s ‘over-supply’ of offshore geological storage assets, such as can be found in the Central North Sea, presents us, as a nation, with an economic opportunity in future to be at the centre of a

inked: Claire Perry and KjellBørge Freiberg sign the mou

hub for the importation and storage of CO2 from Europe. In such a way we can further help address the threat posed by

necessary. Geoffrey Maitland, Fellow of

However this can be tweaked as we go

climate change, while also utilising the

IChemE and a member of the taskforce,

through the 2020s. If what happens in

skills within Scotland’s energy supply

commented on the government’s plans.

2019/2020 receives a good response from

chain.”

“I think it’s a very good response from

the industry and the mechanism is in

the government. My worry is that on the

place then I don’t see why this couldn’t

basis of one cluster you won’t necessarily

be accelerated.”

Action plan

have the scale and the multidimension-

Jenifer Baxter, head of engineering at

The action plan by the Department for

ality to actually bring the cost down as

IMechE, said: “CCUS is a critical part of

Business, Energy & Industrial Strategy

much as you can do.”

the future energy and industrial systems

(BEIS) sets out the next steps that the

The plan outlines numerous steps that

and the government is heading in the

government and industry need to take

will be taken in 2019, including engaging

right direction with providing addi-

in order to deploy CCUS at scale during

with industry to assess the critical chal-

tional funding. However, the amounts are

the 2030s. The BEIS also released addi-

lenges in deploying CCUS, and identifying

somewhat underwhelming and the trans-

tional

potential

existing oil and gas infrastructure which

lation into action in this sector is slow.

business models to establish an incentive

could be re-used for CCUS purposes.

The UK is well-placed to lead the world

for industrial carbon capture in the UK, a

“What they’ve committed to do in 2019

in the development of carbon capture and

study estimating costs of shipping CO2 to

– to get the plans in place, to do the

storage technologies, which are consid-

geological storage sites, and a technical

consultations that are needed to identify

ered critical for decarbonising our whole

advisory on CCUS technologies.

where this first plant is going to be, and

energy system. Deployment of demon-

The action plan includes a commit-

what policy and business model frame-

stration plants and low carbon industrial

ment to invest £20m supporting the

work is needed – is as much as one could

clusters should form a central part of our

construction of CCUS technologies at

conceivably do,” said Maitland. “In fact,

industrial strategy. The renewed focus on

industrial sites across the UK, as part of a

it’s a very packed agenda for 2019 so I

CCUS is welcome, but planning should be

£45m CCUS innovation programme. The

suspect the government, and BEIS in

converted into action soon.”

government has also allocated £315m to

particular, are going to need a lot of help

In the chairs’ summary of the summit,

the Industrial Energy Transformation

from the community to get that in place.”

Perry and Birol concluded: “The summit

Fund for projects that will decarbo-

“I would like to see perhaps less

provided an important opportunity to

nise industrial sites, which includes fuel

caution in the speed in which we bring

build partnerships, share best practices

switching and carbon capture.

the cost down and to provide some task-

and identify the solutions to accelerate

The report includes a response to

ready incentives to business to do things

CCUS deployment. The government of the

recommendations made by the CCUS

quickly whilst the cost is being brought

United Kingdom and IEA will continue

Cost Challenge Taskforce to the govern-

down, rather than to wait until the cost

to support the outcomes of the Interna-

ment in July. The government has agreed

is brought down before going to larger

tional CCUS Summit, including through

to enable the deployment of one CCUS

scale. I think it’s so urgent to do it that it

existing

cluster by the mid-2020s, although the

requires the government to bear its share

Conference of the Parties, and will report

taskforce

that

of the risk in terms of actually getting

progress at the IEA ministerial meeting

a minimum of two clusters would be

this deployed quickly at a larger scale.

in 2019.”

reports

report

examining

recommended

multilateral

initiatives,

the

APD

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 12

NID2 DG.indd 12

06/12/2018 15:13

NEWS in depth

environment

Leaders gather to discuss a greener business future Building a stronger, more resilient, and sustainable economy THROUGHOUT history, industries have

Prepare for failure

to only sell LED bulbs and lighting.

either fought change or embraced it.

Steve Howard, co-founder of the We

Howard said that “when you set a 100%

Now, with the global threat posed

Mean Business coalition, took to the

target you create absolute clarity about

by

prac-

stage to discuss sustainability, attitudes

what the future looks like.” By pushing

tices it is important that industry

to change, and lessons learned as chief

all efforts and innovation towards LED

takes action. This was a key message

sustainability officer at IKEA.

lighting, IKEA not only made a change

current

unsustainable

global

towards sustainability, but it also made

ble Business Summit held in London in

non-profit coalition which works with

its lighting business higher performing.

early November which brought together

some of the world’s most recognised

“Doing what you’ve done last year

global business experts to discuss how

businesses in order to catalyse business

and doing it slightly better, is what we

they are embracing change towards a

action towards the United Nations (UN)

tend to do in larger businesses,” Howard

more sustainable future.

Sustainable Development Goals (SDGs).

said. Because “real change is hard.” And,

Michael Bloomberg, founder of the

It currently has over 1,340 commitments

this is something Ingvar Kamprad, the

host news organisation, said: “We’re

to act, from 827 companies which repre-

now deceased founder of IKEA, under-

hosting

sent a market cap of US$16.9trn.

stood. Kamprad once encouraged IKEA

from

the

The

events

Bloomberg

like

this

Sustaina-

in

cities

We

Mean

Business

is

a

“Sustainability has gone from being

management to achieve more ‘failures’

that we can all work together to build a

optional and local to absolutely about

and ‘fiascos’ because he understood

stronger, more resilient, and sustainable

our future – a defining megatrend,”

that “if you’re going to create change,

economy.”

said Howard. “It’s the most predictable

you have to be prepared to risk failure”,

and consequential trend that will shape

Howard said. Kamprad even offered

the working environment for the rest of

a kr1m (US$110,160) prize for the best

our lives.”

failure.

Bloomberg

around the world to highlight ways

“Sustainability has gone from being optional and local to absolutely about our future”

Waste bread into beer Rob Wilson, “chief toaster” at brewing newcomer Toast, discussed his company’s innovative solution to food waste.

And change in the direction of sustain-

This accounts for 3.3 Gt of CO2 emis-

industry

against

sions, a blue water footprint of 250 km3,

it,” Howard added. So, it is import-

and a land use footprint of 1.4bn ha,

ant for well-led business that can “see

equivalent to 28% of the world’s agri-

the future” to increase efforts towards

cultural land. In the UK alone, 15m t/y

achieving sustainable change. Howard

of food goes to waste, with bread being

added that in order to successfully

a major contributor. Estimates are that

achieve change, businesses have to go

44% of bread is thrown away every year.

is

still

organised

all-in. “It’s a powerful thing to do,” he said.

steve howard: discussed lessons learned at ikea

Globally, one third of food gets wasted.

ability is occurring, “but much of

To tackle this problem, Toast founder Tristram Stuart started a business that

Howard discussed the example of

brews beer using surplus bread. The

IKEA, US going “100% LED”. In 2015 the

idea was inspired by his meeting with

company became the first major retailer

the people behind the Brussels Beer

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 13

NID3 DG.indd 13

06/12/2018 13:52

NEWS in depth

from across the fashion industry to work

a 7,000-year-old recipe for beer brewed

towards a more circular economy.

with bread. Whilst not a completely

Core partners and participants of MFC,

novel idea, having seen how beer was

including Burberry and H&M, are united

brewed for thousands of years, brewing

behind three key principles created to help

with bread is something that Toast

deliver benefits for citizens, the environ-

is attempting to bring back into the

ment, and business. The principles are

mainstream.

to design out waste and pollution; keep

Toast has four founding principles: to produce a high-quality premium product; eliminate bread waste; raise

products and materials in use; and regenerate natural systems. Pam Batty, vice president of corpo-

awareness about food waste in an acces-

rate

sible way; and donate 100% of the profits

“This is not a challenge that one brand or

to charity.

company can solve on their own. It has to

Toast

partnered

manufacturer

Adelie

with

sandwich

foods,

which

responsibility

at

Burberry,

said:

be an industry effort to create real system change.”

donates and delivers surplus bread it

Burberry recently came under fire

would otherwise pay to dispose of. The

for burning unsold clothes, accessories

bread is then used to replace one third of

and perfume. According to Reuters, the

the barley that would typically be used

company destroyed US$40m worth of

in the brewing process.

merchandise last year. The company has

Toast also encourages others to take on its idea, from homebrewers to others

Bloomberg

Project, whose Babylone beer is based on

rob wilson: ‘chief toaster’ at brewing newcomer toast

since announced that it would stop these practices.

less energy than a typical fluorescent

in the industry, and has open-sourced

H&M has also faced scrutiny over the

its brewing recipe, which has been

sustainability of its operations. Last year,

The building conserves water through

downloaded more than 40,000 times.

Danish documentary Operation X accused

use of rainwater from the roof, cooling

Toast collaborates with other brewers

H&M of destroying unsold, but usable

tower blow-off and grey water sources,

around the world to encourage them to

clothes. And, earlier this year the New York

which are captured and then treated for

brew with bread, and plans to launch a

Times reported that H&M was hoarding

use in vacuum flush toilets. In total, the

platform to connect brewers with bakers

US$4.3bn worth of unsold inventory.

systems allow net zero use of water for

in order to tackle the issue of food waste at a regional level. “There

are

commercial

business

office lighting system.

flushing. It’s estimated that the conser-

Award-winning building

vation systems will allow for 25m L/y of water.

solutions that are sustainable,” said

The summit was hosted at Bloomberg’s

Wilson. “We are facing catastrophic

European headquarters in London. Lee

enable the Bloomberg building to save

climate catastrophe and we can address

Ballin, event host and lead of sustainable

73% in water consumption, and 35% in

this issue, but we must act now.”

business programmes at Bloomberg,

energy consumption and associated CO2

called it “the world’s most sustain-

emissions, compared to conventional

ably-designed office building”.

office buildings of the same size.

The importance of collaboration and partnership

These

features,

alongside

others,

The 1.1m ft2 building has a range of

The building was awarded the Royal

features that help make it “greener”. Its

Institute of British Architects’ 2018

The textiles industry results in an esti-

façade features distinctive bronze blades

Stirling Award, one of the world’s most

mated 1.6bn t/y of greenhouse gases.

which allow the building to “breathe”.

prestigious architectural prizes.

That’s more than international flights

The blades open and close, allowing

and maritime shipping combined. The

the building to take advantage of the

seen how investing in sustainability

industry also results in massive amounts

temperate London climate. The natural

helps our business, by saving us money,

of waste.

ventilation system reduces dependency

by cleaning the air our employees and

“Every second there’s the equivalent

on mechanical ventilation and cooling

clients breathe, and by helping us retain

of a truckload of clothes that is going to

equipment, enabling savings in energy

people that care about the environment

landfill or for incineration,” said Francois

consumption.

and climate change.”

Michael

Bloomberg

said:

“We’ve

Ceiling panels with a petal-leaf design

And that might provide even more

was

combine heating, cooling, lighting and

reason to embrace change and, as

launched by the Ellen MacArthur Foun-

acoustic function. The system incorpo-

Howard said, “go for the million-krona

dation in 2017 and brings together leaders

rates 500,000 LED lights and uses 40%

prize”.

Souchet, leader of MFC. Originally named Circular

Fibres

Initiative,

MFC

AJ

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 14

NID3 DG.indd 14

06/12/2018 13:52

NEWS in depth

environment

How to significantly reduce the cement industry’s emissions Report claims 95% reduction is possible by 2050 A REPORT has outlined how the cement and concrete industry can reduce its CO2 emissions by 95% by 2050. The report, A sustainable future for the European cement and concrete industry, was commissioned by the European Climate Foundation and produced by the Swiss Federal Institute of Technology (ETHZ), Zürich, and the Swiss Federal Institute of Technology (EPFL), Lausanne. Cement production is responsible for 8% of global CO2 emissions. More than 60% of emissions in cement production comes from the chemical breakdown of the limestone used to produce the clinker, which is one of the major components in cement. Most efforts to date have been focussed on

have limited applications and technical

clinker) requires R&D by cement plants,

reducing the CO2 footprint of the cement,

difficulties.

but the cement needs to be bought by

but the key finding of the report is that

Ordinary Portland cement contains 95%

efforts to reduce CO2 need to be carried out

clinker, but European standards allow the

across the entire value chain.

clinker level to be between 5% and 95%

concrete companies, and preferred by construction companies.

for different cement types. Reducing the

Reducing emissions across all stages

amount of clinker in cement by substitut-

Including cCS

ing some of the clinker with other products

The report outlines a scenario which

can

example,

makes changes across the full value chain

The report identifies four areas across

by-products from other industries such as

reduce

emissions.

For

with only moderate investment, and can

the value chain where emissions can be

blast furnace slag from the steel industry

reduce CO2 emissions by 75% by 2050

reduced – clinker production, cement

or natural products like limestone can be

compared to 1990 levels. Including CCS

production, concrete production, and at

used. However, the report notes that vari-

with this scenario would increase this to

the construction level. It identifies proven

ations in clinker content can influence the

a 95% CO2 reduction. The report recom-

technologies that can be implemented

applications of the cement.

mends that CCS should be pursued with

There is often 20% more cement in

the objective of meeting post-2050 climate

Clinker produces around 875 kgCO2eq/t

concrete than required by the standard,

targets, but there are technical issues to be

clinker, and 40% of this comes from

so reducing the amount of cement used

solved if it is to be implemented on a large

the energy required to heat limestone.

in concrete will lower emissions. It is also

scale within the next two decades. The

However, using greener fuels for energy

possible to reduce the amount of concrete

main limitation with CCS is the extreme

can reduce the emissions. Improved kiln

used

cost, as the investment cost is twice as high

technologies can reduce the emissions,

compromising safety.

quickly across the chain.

at

the

structural

level

without

as for a new cement plan and the power

as using dry kilns instead of wet kilns is

Emissions reduction efforts also need

consumption would need to be increased

more energy efficient. Alternative binders

to be connected across the value chain.

drastically. The report says that net zero

can also be used instead of conven-

For example, increasing the use of blended

emissions would be technically feasible,

tional clinker, although some of these

concretes (ie substituting some of the

but only with extreme investments.

APd

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 15

NID4 DG.indd 15

06/12/2018 13:53

NEWS round-up

environment

Teesside to host world-first CCUS plant THE Oil and Gas Climate Initiative (OGCI) has announced a strategic partnership with six oil and gas majors to construct the world’s first gas-fired power plant that will

teesside: best location for full-chain ccus

deploy full-chain carbon capture, utilisation, and storage (CCUS) at Teesside, UK. The partnership between the OGCI Climate Investments, BP, ENI, Equinor, Occidental Petroleum, Shell, and Total selected Teesside as the best location for a full-chain CCUS facility out of 50 other potential sites. The Clean Gas Project will generate power using natural gas, capture the CO2 emissions, and transport the CO2 via a pipeline for storage under the Southern North Sea. The OGCI said that it could form the heart of the Tees Valley CCUS Cluster. Ben Houchen, Tees Valley mayor and chair of the South Tees

biggest companies in the world choosing Teesside to develop this

Development Corporation, told The Northern Echo: “This multi-

ground-breaking technology – a world first which will also support

billion pound energy project will pave the way for our region

the development of our huge processing and chemicals industry.”

to become the clean energy powerhouse of the UK, creating and safeguarding thousands of jobs. We have got some of the

Work on the project will begin in 2020, with plans to be operational by 2025.

environment

safety

Shell commits to stricter targets on cutting emissions

Leak causes explosive chain reaction

SHELL has given in to pressure from investors to commit to

23 and injured 22 was caused by a vinyl chloride gas leak at its sub-

specific goals in limiting climate change.

sidiary Hebei Shenghua Chemical Industry Company, reported Reuters.

It will set specific three to five-year net carbon targets every

CHEMCHINA has released a statement stating that a blast which killed

The company is located in Zhangjiakou, China.

year from 2020 as part of its long-term plan to cut emissions

The explosion occurred on 21 November as acetylene was being

by 20% by 2035 and 50% by 2050. As part of this, it plans to

delivered to nearby Haipo’er New Energy Technology Company,

link targets with its executive remuneration policy, which could

reported official news agency, Xinhua.

affect the top 1,200 employees in the company. The policy will need to be approved by shareholders in 2020. In 2017, Shell had announced that it would cut its emissions

A vinyl chloride gas leak at the chemicals company caused a truck to explode. That explosion led to a series of blasts that resulted in the casualties, and ignited 50 vehicles, Xinhua reported.

by 50% by 2050, but investors criticised its long-term plan,

ChemChina released a statement apologising for the accident,

saying that it lacked any binding targets. While short-term

saying that it reflected serious problems in its safety management

targets had already been set by BP and Total, Shell had resisted

systems.

doing the same. Shell defeated a motion by investors in May this

China has struggled to regulate its industrial safety in the wake of

year, which aimed to bring the company’s emissions in line with

rapid growth, and this accident is just the latest in a series of indus-

the Paris Agreement. At a company event in July, Shell CEO Ben

trial accidents that have angered the public. Earlier this year 19 people

van Beurden said that it would be “foolhardy” to expose Shell to

were killed in a blast at a chemical plant.

legal challenges should it fail to meet reductions targets.

Often mentioned is the 2015 explosion of a chemical site in

The new targets will incorporate emissions from fuel burn-

Tianjin, China, which killed 165 people and injured a further 798. The

ing by customers and will see Shell increase the share of gas in

cause was found to be the improper and illegal storage of hazard-

its production mix from 50% to 75%.

ous materials. 49 people were convicted for their involvement. The

Shell will publish data on its net carbon footprint in its 2019 sustainability report.

Chinese government cracked down on safety following the incident in Tianjin, but fatal accidents continue to be relatively common.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 16

roundup930 DG.indd 16

06/12/2018 16:05

GE Renewable Energy

NEWS round-up

batteries included: Tullahennel’s turbines will inject on-demand power into ireland’s grid

business

Albemarle mulls Aussie lithium partnership ALBEMARLE has signed an exclusivity

agreement

Resources

(MRL)

with for

a

Minerals potential

joint venture (JV) to own and operate a lithium mine and processing facilities in Western Australia. The companies would ultimately develop an

integrated

lithium

hydroxide

operation at the site that could help to serve growing demand for its use in batteries. Wodgina is a world-class hard rock lithium deposit located in the Pilbara region of Western Australia. The deposit has an estimated mine life of 30 years.

energy

Albemarle, also the world’s largest producer of lithium, would invest

An ‘evolution’ in renewable energy

US$1.15bn for a 50% stake in a JV set

GE is close to completing the world’s first commercial wind project with integrated

is set to triple over the next decade.

to help meet the rising demand for its use in electric car batteries. Demand

power storage. Located in County Kerry, Ireland, the project could help the country

In addition to owning and oper-

cope with rapidly increasing energy demand, and achieve its renewable energy goals.

ating the mine, Albemarle and MRL,

The wind project, named Tullahennel, consists of 13 wind turbines which together

the leading mining services company,

have a total capacity of 37 MW. Each turbine is integrated with a lithium ion battery,

would build a spodumene concen-

roughly the size of a small car, located at the base of the tower. Each battery can store

tration plant. Spodumene is a source

up to 69 kWh of electricity, which can be fed into the grid as demand outstrips supply.

of lithium and is planned to be used

Tullahennel is a crucial project for Ireland. The country’s energy demand is expected

as feedstock in a future lithium

to increase by 15–36% over the next decade. A report by EirGrid, the Irish trans-

hydroxide plant. After construction

mission grid manager and operator, said that the driving factor in this increase was

and ramp-up the plant is expected

the growth of data centres. The centres already consume 6% of Ireland’s electricity

to

produce

and now under a 15-year purchase agreement all of Tullahennel’s power will go to

of

6%

Microsoft Corp data centres.

from Wodgina.

up

to

spodumene

750,000

t/y

concentration

In addition, this evolution in renewable energy could help Ireland achieve the gov-

The JV would also see the compa-

ernment’s mandate to generate 40% of its electricity from renewable sources by 2020.

nies fund, design, build, and operate

Although Ireland ranks highly among EU countries in clean energy use, it still gets 9%

a lithium hydroxide plant in stages

of its energy from burning peat, which has adverse environmental impacts.

at Wodgina. The plant would be built

Tullahennel’s turbines recently went online, and the battery systems are in the final

using Albemarle’s core design. In the

stages of testing on-demand injection of power into the grid. According to a project

first stage, once fully commissioned,

update from GE Renewable Energy (GERE), early tests were successful and show that

it is expected to produce at least

the system is able to quickly adjust to grid demand and turbine power generation.

50,000 t/y of battery-grade lithium

Steve Bravo, wind and hybrids project manager at GERE, said: “The storage indus-

hydroxide. At least 100,000 t/y of

try is still figuring out what the most viable solution may be.” He added that “from a

lithium hydroxide is expected in the

technical standpoint, this is a proof point of how to use and integrate storage directly

second stage.

into a turbine and see how it will perform.”

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 17

roundup930 DG.indd 17

06/12/2018 16:05

BASF

NEWS round-up

environment

Drax commissions BECCS pilot plant DRAX has started commissioning a bioenergy with carbon capture and storage (BECCS) pilot plant – the first project of its kind in Europe. The pilot plant is located at the Drax station in North Yorkshire, the UK’s largest power plant. If the sixmonth project is successful, a ton of carbon dioxide will be captured each day.

industry

Over the summer, work was carried out to assess if the capture

BASF plans to boost growth but keep emissions flat

solvent developed by C-Capture was

BASF has outlined a strategy to outpace average global chemical sales while stagnating

of flue gas desulfurisation (FGD)

emissions.

absorbers at the power station was

“BASF commits to keeping its greenhouse gas emissions flat at the 2018 level until 2030 – even though we are targeting considerable annual production growth,” said company chair-

compatible with the biomass flue gas at Drax Power Station. The work proved successful. A lab-scale feasibility study of the re-utilisation

also carried out successfully. C-Capture has now moved on to the second phase of the pilot, which is the

man Martin Brudermüller. The chemicals major is targeting an annual increase in earnings before tax (EBITDA) of

installation of the demonstration unit.

3–5%. This is down from the 8% average increase it has achieved since 2012, against the back-

Once it has been commissioned the

drop of a 3.7% annual growth in global chemicals demand.

plant will isolate carbon dioxide pro-

“We want to grow stronger than the market, and we aim to grow our sales volumes above global chemical production growth,” said CFO Hans-Ulrich Engel.

duced during combustion of biomass. If the BECCS pilot is successful, Drax

To achieve these targets, BASF will increase its development of highly integrated facilities

plans to examine options for a similar

– known as Verbund plants, which it claims already help make annual cost savings of at least

repurposing of existing infrastructure

€1bn (US$1.14bn) on raw materials and energy. In July, BASF signed an MOU for a US$10bn

to deliver more carbon savings.

Verbund chemicals site in Guangdong, China. The strategy calls for improvements in management, efficiency and integration of its plants and it will purchase a greater share of electricity from renewable sources.

Will Gardiner, CEO at Drax Group, said: “If this project is successful, it could enable Drax to become

“Given the already very high technological standards at our plants, this is a very ambitious

the world’s first carbon negative

goal that will require exceptional creativity to do things differently,” said Brudermüller. The

power station – something many

company has reduced its greenhouse gas emissions by 50% in absolute terms compared to

would never have dreamed possible a

1990 levels while doubling production volumes. Further savings will require that governments

decade ago.

across the world provide what the company describes as a suitable regulatory environment. Technology has a key role to play too. BASF’s staff are already using augmented reality

BECCS is is one of several greenhouse

gas

removal

technologies

to bolster operations and the company has installed its own supercomputer to help improve

that were assessed in a joint report

research. It says digitalisation will continue to boost growth and efficiency, for example allow-

released in September this year. The

ing it to simulate processes or investment ideas, and is aiming to digitalise processes at more

Royal Society and the Royal Acad-

than 350 of its plants by 2022. This effort, it says, will help the company “stay ahead of its

emy of Engineering estimated that

peers in the chemical industry”.

BECCS could be used to capture

It is making organisational changes too, expanding its current four business segments to six, in a move designed to match its businesses against those of its competitors. “Our main emphasis will be on designing processes to be efficient and reliable. Businesses

50 Mt of carbon dioxide by 2050, which is approximately half the UK’s emissions target.

where we cannot achieve such a position will eventually be exited,” said Brudermüller.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 18

roundup930 DG.indd 18

06/12/2018 16:05

NEWS round-up

environment

ExxonMobil contributes US$10m to the Singapore Energy Centre partnership EXXONMOBIL will contribute US$10m to the Singapore Energy Centre. The Singapore Energy Centre was created as a joint effort to transform the energy landscape and address future sustainability challenges. ExxonMobil will be the first founding industrial member of the centre, which is co-led by the Nanyang Technological University (NTU), Singapore, and National University of Singapore (NUS). ExxonMobil signed a memorandum of understanding to become a founding member in November 2017. Its five-year funding commitment represents the company’s first such research and development partnership outside of

at NUS, said: “This strategic partnership will enable consor-

the US. As part of the partnership, ExxonMobil researchers and

tium members to identify issues of common interest to the

scientists, as well as other industry contributors, will collaborate

industry and co-develop solutions with the two universi-

with faculty and students at the universities. ExxonMobil will

ties. This approach will bridge the gap between early-stage

support the centre’s wide range of early-stage research projects,

research and economic-centric applied research, both of

which are focussing initially on areas including bioscience, CCUS,

which are needed for development of long-term sustainable

and energy- and water-efficiency.

energy solutions.”

These research projects embody the concept of a “green

Lam Khin Yong, vice president of research at NTU, said:

economy” which is a key focus of the Sustainable Singapore

“This joint centre will take ideas nurtured at the lab into

Blueprint. The blueprint aims to transform Singapore into a hub

industry, and also study the environmental impact of inno-

for sustainable development that encourages businesses to adopt

vations, as well as business and economic models for its

greener practices.

research projects.” NTU and NUS are extending invitations to

Chen Tsuhan, deputy president of research and technology

other leading companies to join the centre.

safety

business

Explosion kills one at US Ecology site

Fluor awarded CHP contract at Pembroke refinery

AN explosion at a US Ecology facility in Idaho, US, has killed one worker and injured three. The explosion occurred on 16 November

FLUOR has been awarded a contract for Valero Energy’s com-

during a routine process involving powdered magnesium products.

bined heat and power (CHP) cogeneration project at its Pembroke

Officials said a series of chemical reactions followed the initial blast.

refinery in Wales.

Equipment operator Monte Green was killed in the explosion.

The contract includes design, procurement, construction,

Three other people were hospitalised for non-life threat-

and commissioning support for the new £127m (US$165m)

ening injuries. The Environmental Protection Agency and the

45 MW natural gas-fired system. The turbine will supply power

Occupational Safety and Health Administration were at the site on the

and steam to the refinery to improve its energy efficiency and

following day. There was no threat to the public, and no evacuations

control future energy costs. “We are pleased to assist Valero with this notable project

took place. Simon Bell, the company’s vice president of operations, said of

that will enhance energy efficiency and sustainability at the

the building: “Most of the skin has been blown out, and much of the

refinery, which is of significant importance for the economy of

metal has been bent. It would have been a large explosion, based on

Wales,” said Al Collins, president of Fluor’s Energy & Chem-

the damage to the building.”

icals business in Europe, Africa and Middle East. “Fluor will

US Ecology takes hazardous inorganic waste such as arsenic,

utilise its in-depth cogeneration expertise together with previ-

lead, zinc, cadmium and other metals and converts them to non-

ous experience of working at the Pembroke Refinery to deliver a

hazardous residues, which are then buried on site.

capital-efficient project.”

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 19

roundup930 DG.indd 19

06/12/2018 16:05

NEWS Research & Development

business

Report finds more ‘D’ needed in UK R&D A Royal Academy of Engineering report has found that more support is needed for the final development of new technologies in the UK. Senior business decision makers from large and small companies took part in the research for the RAEng report, Increasing R&D Investment: Business Perspectives. The report found that there is a lack of support for the development and demonstration of innovative technologies in the UK compared to other countries such as the US and Germany. During late-stage development, companies can demonstrate the potential of their technologies, or test them in real-world situations. More support for the development stage

already attract engineering businesses to locate their high quality

would encourage further investment in R&D, according to the

early-stage R&D activities here, not least our world-class

report. The report describes the advantages of locating R&D in

academic research base and its excellent collaboration with industry.

the UK, and identifies areas where improvement could occur, such

Unfortunately, this is undermined by gaps in the R&D and innovation

as having a more joined-up government approach and improved

system at a highly risky and expensive time in the development

innovation across sectors.

cycle. Plugging these gaps would help innovative engineering

Dame Ann Dowling, president of the Royal Academy of Engineering said: “The UK undoubtedly has many attributes that

businesses, boost productivity, and create better jobs and social outcomes in the UK.”

process

materials

Demonstration plant for groundbreaking chemicals technology

The next step for CO2-based plastics

PHOTANOL,

company,

produce synthetic sports flooring. The world-first subfloor of this

is building a demonstration plant for what it claims is a

kind has now opened in a competitive hockey venue facility in Krefeld,

a

platform

renewable

chemicals

COVESTRO’s carbon dioxide-based polyols have been used to

“ground-breaking” chemicals technology which produces

Germany, and marks the next step in the use of CO2 for plastics

chemical building blocks from sunlight and CO2. The facility will

production. The environmentally-friendly technology enabling the

be located at a site in Delfzijl, the Netherlands, owned by part-

use of CO2 as a raw material for production was developed by polymer

nering chemicals company Nouryon.

company Covestro and its partners. It allows up to 20% of the fossil

Using genetically modified bacteria, chemicals such as organic acids and terpenes can be produced from sunlight and

fuels required for the production to be replaced with carbon dioxide, to act as an alternative carbon source.

CO2. Currently, 17 products can be produced by this technol-

The CO2 is used to produce a material called cardyon, a polyol.

ogy. The demonstration plant will focus on producing three

So far cardyon has been used to produce soft polyurethane for

products, all of which are organic acids for the production of

mattresses and upholstered furniture and is already on the market.

polymers. The technology is currently at the pilot plant stage. The demonstration plant is part of an €8m project (US$9.1m)

Covestro has now developed a CO2-based binder which has been used in sports subflooring. Polytan, an active sports flooring producer

prior to scaleup. The modularity will allow the facility to be built

owned by Sports Group, was the first customer of the new CO2-based

up for commercial purposes following a demonstration of tech-

binder. It uses the material to produce elastic underfloor together

nological and economic viability. However, the commercial

with rubber granulate.

build may be at a different location. Construction is set to begin in 2019, with the expectation of being fully operational by the end of 2020. Veronique de Bruijn,

Markus Steilemann, CEO at Covestro, said: “The use of carbon dioxide as a new raw material is a promising approach for making production in the chemical and plastics industries more sustainable.

CEO of Photanol, said the company is “keen to prove to the world

“This way, we use CO2 in a closed-loop process and save oil. On

that we can make a big difference by producing clean chemicals

this basis, we want to offer a comprehensive product portfolio for as

while reducing the CO2 burden on the environment.”

many areas of application as possible.”

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 20

r&D930 DG.indd 20

06/12/2018 17:39

NEWS Research & Development

materials

MOF offers more efficient ethylene separation (MOF) containing iron-peroxo (Fe2(O2)) sites which could reduce the amount of energy required to extract ethylene. Ethylene, polymerised for use in everyday plastics, is the largest feedstock in the petrochemical industry, with 170m t produced worldwide in 2016. It is typically produced by steam cracking or thermal decomposition of ethane. An important step is the separation of ethylene from other hydrocarbons in order to obtain polymer-grade purity. The bulk of the hydrocarbon mixture is made up of ethylene and ethane, and separating those two hydrocarbons is by far the most energy-intensive step. Conventional ethylene separation is carried out via a cryogenic

a star is born: promising Iron-based mOF with peroxo groups preferentially adsorbs ethane (blue and white) for separation of ethylene (orange and white)

W.Zhou/National Institute of Standards and Technology

RESEARCHERS have developed a metal-organic framework

distillation process which uses temperatures below -100°C. Sorption methods offer an energy-efficient separation alternative that can be performed under ambient conditions.

comparison to other adsorbents which require four cycles to reach 99.95% polymer-grade ethylene purity.

Using sorption methods for ethane or ethylene separation

Highly efficient separation was also achieved for the

instead of the cryogenic process might reduce energy require-

separation of ethylene from 10:90 ethane/ethylene mix-

ments by 20%.

tures and 10:87:1:1:1 ethane/ethylene/methane/hydrogen/

Researchers in the US, China, and the Netherlands have

acetylene mixtures.

developed a MOF that separates the hydrocarbons by adsorb-

Wei Zhou, a senior staff scientist at the National Insti-

ing ethane through iron-peroxo sites. This is preferable to

tute of Standards and Technology (NIST) Centre for Neutron

previous adsorbents that preferentially adsorbed ethylene

Research (NCNR), said the MOF might still require additional

which then required subsequent desorption for use.

work.

Preferential adsorption of ethane instead of ethylene could

“We proved this route is promising,” Zhou said, “but

reduce the energy needed for adsorption-based separation by

we’re not claiming our materials perform so well they can’t

about 40%.

be improved. Our future goal is to dramatically increase their

In one adsorption cycle the MOF achieved ≥99.99% pure ethylene from 50:50 ethane/ethylene mixtures. This is in

selectivity. It’s worth pursuing further.” Science http://doi.org/cwr6

research & development

Recycling carbon dioxide in steel production A EUROPEAN project is researching how to use the carbon diox-

same time. It is not yet known how much CO2 can be saved with

ide produced during steelmaking to make methane and methanol.

the new process.

The project, known as i3upgrade, is led by researchers at

The researchers are also investigating a new concept for a

Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) and

reactor that would use the heat produced during methanation.

other partners include voestalpine Stahl and AirLiquide. The aim

Incorporating heat pipes into the reactor would allow the heat

of the project is to research the best methods for reducing the CO2

to be used for gasification or other downstream processes. The

that is produced as a byproduct during steel production.

improved heat dissipation would also cut costs and complexity

By combining the blast furnace gases with hydrogen that has been produced from renewable energy, the researchers plan

compared to traditional methanation where the temperature has to be gradually lowered during several steps.

to produce methane and methanol. Natural gas is an important

The project has been awarded €3.3m (US$3.75m) in funding

energy source for steelworks and by synthesising methane they

from the EU and European Research Fund for Coal and will be

can provide their own power and use some CO2 emissions at the

completed by November 2021.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 21

r&D930 DG.indd 21

06/12/2018 17:39

Tobias Hang/Fraunhofer IMM

NEWS Research & Development

recycling

Recycling mixed plastics RESEARCHERS in the UK are working to develop new technologies for dealing with mixed plastic waste. The project involves scientists and engineers from the University of Bath’s Centre for Sustainable Chemical Technologies (CSCT) and the University of Manchester. During recycling, plastics are sorted by type ahead of processing, but researchers are now investigating ways of chemically

biofuels

breaking down mixtures of plastics into

Mobile plant produces fuel from waste wood

could then be used to manufacture new

TWELVE research groups from seven countries have developed a sustainable method

plastics that gets recycled.

their constituent molecules. The molecules

for producing biofuel from wood waste. The process takes place in a mobile unit (pictured above) which has the potential to decentralise fuel production.

plastics, or to make other high-value products. This research might allow households to simply throw all plastic into one recycling bin, helping to increase the amount of The project is led by Arthur Garforth, director of teaching and learning in the

Wood waste and tree bark are ideal raw materials as they don’t need to be specially

school of chemical engineering and ana-

cultivated and don’t compete with food production. Wood waste is also available in large

lytical science at Manchester, and builds on

quantities – for example in Germany around 12m t/y is available, compared to a gasoline

his previous research using hydrocracking

consumption of 16m t/y. When it is combusted, it only releases the CO2 that was absorbed

technology and heterogenous catalysts.

by the trees as they grew, making it carbon neutral.

“We demonstrated we could reduce

The aim of the EU-funded project BIOGO was to develop a biomass-to-liquid plant

temperature by 50–100°C and pressure of

capable of producing sustainable synthetic fuel. The plant is transportable and has a mod-

hydrogen was at the low end around 30 bar,

ular infrastructure that contains catalytic reactors for each process step.

but the reaction was complete in around 3–5

“The goal of the BIOGO project was to develop a plant that could fit in a container with

mins,” Garforth said, compared to 30-90

standard dimensions of 12 x 3 x 3 m, and that could accommodate all the procedural and

minutes in previous studies. He noted that

processing steps,” said Gunther Kolb from Fraunhofer Institute for Microengineering and

current feedstock recycling methods are

Microsystems, who coordinated the project. “At the same time, we had to make the man-

typically unselective and give an oil con-

ufacturing process as environmentally-friendly and resource-efficient as possible.”

taining a large range of hydrocarbons. “We

Wood waste is first converted into pyrolysis oil, which is the liquid fraction produced by

demonstrated the ability to take mixtures of

fast, thermal decomposition of organic matter in the absence of oxygen. The pyrolysis oil

post-consumer polymer waste and gener-

is then converted into syngas by adding heat, air, and steam. In the next step, methanol is

ate highly branched saturated hydrocarbon

produced from the syngas, and finally gasoline is produced from the methanol by extract-

liquid product rapidly at reduced tempera-

ing oxygen. One of the key goals of the project was to advance the catalysts needed for the

ture and pressure of hydrogen.”

processes. In the methanol-to-gasoline (MTG) step, synthetic gasoline is generated using

He said the rapid reaction and ability

zeolite catalysts. Zeolite catalysts had been used for MTG previously, but the newly devel-

to deal with unsorted waste opens up the

oped metal-oxide zeolite catalyst has significantly improved stability and a high activity.

possibility of continuous processing, and a

The new catalyst also reduces the dependence on rare earth oxides and precious metals.

number of companies are interested in the

The fuel can be generated wherever there is sufficient wood waste, so unlike petro-

approach. Currently, “our aim is to exploit

leum, it doesn’t need to be transported from refineries to filling stations. “An important

heterogeneous catalysts, including sulfated

component of the BIOGO concept is decentralised production,” said Kolb. “To achieve

zirconia, clays, waste FCC catalysts and

this, we have developed mobile production units that can be housed in containers and

zeolites to tailor the product stream,” said

installed where they are needed.” The prototype container was designed to accommodate

Garforth. The researchers are also aiming

even larger reactors and the teams are planning to develop the plant further with a goal of

to expand the feedstock including thermo-

producing up to 1,000 L/d of synthetic gasoline.

sets that cannot be successfully remoulded or reheated after their initial heat forming.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 22

r&D930 DG.indd 22

06/12/2018 17:39

NEWS Research & Development

catalysis

New catalyst reduces carbon dioxide emissions in coal-to-liquids process Eindhoven University of Technology/Bart van Overbeeke

A CATALYST has been developed that almost eliminates carbon dioxide emissions in the Fischer-Tropsch process in the conversion of coal-to-liquid fuels. In the coal-to-liquids (CTL) process, the coal is first converted to syngas. It then undergoes the water-gas shift (WGS) reaction, which removes some of the carbon monoxide (CO) from the syngas by converting it to CO2, and this is followed by Fischer-Tropsch (FT) to create the liquid fuels. The iron-based catalysts currently used in the FT reaction convert 30% of the CO into CO2 which is released into the atmosphere. Capturing the CO2 at this stage is extremely challenging, as the gas mixture contains many components, such as hydrocarbon gases, which are difficult to separate from the CO2. Cobalt-based catalysts are a possible alternative to iron-based

ironing out CO2 : Emiel Hensen and Wei Chen from Eindhoven University of Technology

catalysts as they mainly produce water rather than CO2, but they are expensive. Iron-based catalysts are also preferred due to their tolerance to sulfur and high operational flexibility. Researchers in the Netherlands and China have now devel-

CO2 is still produced during the preceding WGS reaction. However, it is much easier to remove CO2 from the WGS stage, and carbon capture after the WGS reactor is already a proven technology.

oped an iron-based catalyst that produces almost no CO2 in the

“We are aware that our new technology facilitates the use of

FT reaction. They discovered that CO2 is released when an impure

coal-derived fossil fuels,” said lead researcher Emiel Hensen of

iron catalyst is used so they produced a pure form of an epsi-

Eindhoven University of Technology.

lon iron carbide which generates very little CO2. These types of

“However, it is very likely that coal-rich countries will keep

catalysts had not been stable enough for the FT process, but

on exploiting their coal reserves in the decades ahead. We want

the researchers developed a new method to produce it by care-

to help them do this in the most sustainable way.” The new cata-

fully controlling the pre-treatment and carburisation conditions,

lyst will reduce operating costs by around €25m/y (US$28.7m/y)

where iron absorbs carbon during a heating process. The new

for a typical CTL plant. The researchers also expect that it could

catalyst remains stable under industrial processing conditions of

be used with waste or biomass as a feedstock in the future rather

2.3m Pa and 250oC for at least 150 hours.

than coal.

While the CO2 can be almost eliminated from the FT reaction,

Science Advances http://doi.org/cv94

water treatment

Novel particles for photocatalytic water treatment RESEARCHERS at Rice University, US, have developed novel micro-

(ROS) produced by the titanium particles.

metre-sized, titanium dioxide (TiO2) particles that can trap and

The particles are better performing than the commerciallyavailable

degrade bisphenol A (BPA). Further development could lead to novel

TiO2 catalyst P25 (Evonik), exhibited by faster removal of contam-

water treatment.

inants. In addition, the developed particles can be easily recovered

BPA is a synthetic chemical used to make plastics. It is commonly used to coat the insides of food cans, bottle tops, and water supply lines. Low-level exposure is considered safe, although prolonged exposure is thought to affect health.

using microfiltration and then recharged with cyclodextrin for further use. 200 mg of the spheres per litre of water degraded 90% of the BPA in one hour. The process took twice as long using TiO2-HS

The particles use surface-attached cyclodextrin molecules – cyclic,

particles without cyclodextrin attached. Lead researcher Danning

sugar-based molecules - to trap BPA. Exposure of the particles to UV

Zhang reported the catalyst is first generation work and requires fur-

light enables photocatalytic degradation by reactive oxygen species

ther development including extending the lifetime of the coating.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 23

r&D930 DG.indd 23

06/12/2018 17:39

feature manufacturing

Producing Graphene

at Scale

The challenge for chemical engineers JASON STAFFORD, OMAR MATAR, AND CAMILLE PETIT DEPARTMENT OF CHEMICAL ENGINEERING, IMPERIAL COLLEGE LONDON

J

UST over a decade ago, the isolation of graphene created a

What is graphene?

major stir in the scientific community. At the time, it was

Graphene is in a category that’s known as a two-dimensional

a material that many believed could not be stable enough

(2D) material. It is a flake made from carbon and is just one

to exist. But it was found not only to be stable, but to possess a

atom thick. This monolayer of carbon atoms is arranged in a

range of properties so extraordinary that it is regularly labelled

2D honeycomb lattice, illustrated in Figure 1 amongst other

as a “wonder material” – a material that will revolutionise every

graphene-based materials. Graphene’s unique properties are

aspect of our technological world. Such promise and attention

what make it such an exciting prospect, which, if realised on

has put graphene under the spotlight.

a large scale, could have far reaching benefits to society. Its

So when we look around at our emerging technologies, why has

electronic properties, such as carrier mobility and current

graphene apparently not delivered? In this article, we discuss one

density, exceed many other conductors in use today. It is also

of the biggest challenges that is blocking its widespread adoption:

an effective heat conductor, with a thermal conductivity that is

how do we make high quality material on a large scale? It is the

several times greater than copper. In 2D form, it is the strong-

first step before it can be used in any technology, and a challenge

est material known. All this, and more, from a material which

which is particularly suited to the chemical engineering discipline.

is 98% transparent.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 24

graphene DG.indd 24

06/12/2018 13:37

feature manufacturing

Figure 1: Illustrations and micrographs of Graphite, Graphene, and the other forms of graphene-based materials1. Although graphene is a monolayer, the name has been used somewhat ambiguously to describe other useful forms of the layered material. These include few-layer graphene, graphene oxide, and reduced graphene oxide. Beyond ten atomic layers, the electronic properties of the material are no longer distinct from the bulk 3D graphite crystal2.

REDUCTION METHOD

GRAPHITE

A

GRAPHENE

B

2.0 nm

50 nm

MULTI-LAYER GRAPHENE (FEW-LAYER GRAPHENE)

C

GRAPHENE OXIDE

REDUCED GRAPHENE OXIDE

D

E

60 µm

500 nm

1 nm

Why all the attention?

scientific articles that have been published1. This covers topics

Graphene’s exceptional properties are central to why it is a

from fundamental condensed-matter physics to the develop-

special case. This is not, however, the only reason why it has

ment of novel graphene-based devices across a range of fields

reached rapid fame. The simplicity with which it was first

including photonics, optoelectronics, energy storage and

isolated is so relatable, irrespective of whether or not you have

conversion, flexible electronics, sensors, composites and

a scientific or engineering background, that it was quick to gain

coatings, and biomedical applications4.

traction in the media. Here is a single atomic layer material,

Why then, has the introduction of graphene been limited to

touted to change the technological landscape, that can be made

only a handful of commercial products? The broad applicability

using some sticky tape and graphite from our pencils. A Nobel Prize followed, six years after this ground-breaking research on graphene was published3, making it one of the fastest times between discovery and award in the physics category. In terms of a science outreach story, it began with the perfect script and

Figure 2: Growth in number of publications on Graphene and Graphene Production topics1 105

Here is a single atomic layer material, touted to change the technological landscape, that can be made using some sticky tape and graphite from our pencils Now the dust has settled and we are past the hype. For some, the frequent attention that graphene receives, combined with its lack of visibility in our everyday lives, has given the impression that it has not delivered on what was expected. For others,

NUMBER OF PUBLICATIONS

quickly achieved stardom on a global stage thereafter.

Topic: ‘Graphene’ Topic: ‘Graphene’ and ‘Production’

104 ~t2.5

103

Novoselov et al (October2004)

~t3

102

101

Increased research on production begins in 2007–2008

particularly those of us working in this field of research, the outlook is positive and developments are happening faster than ever. Graphene has continued to serve as an excellent platform in academic and industrial research. Figure 2 shows this through the year-on-year increase in the number of

10 0

2000 2002 2004 2006 2008 2010 2012 2014 2016 YEAR

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 25

graphene DG.indd 25

06/12/2018 13:37

feature graphene production

and potential of graphene has not gone unnoticed by national

in some applications (eg photovoltaic cells, microelectronic

and international funding bodies. Large-scale consortia and

devices), their effect is less of a concern in others (eg compos-

research centres have been formed across the globe, all with

ites, inks). For now at least, one size does not fit all. What’s

the aim of translating graphene research from the lab to real-

common, however, is that there are process engineering chal-

world solutions. In 2013, Europe started its biggest ever research

lenges across both production routes.

initiative, creating a Graphene Flagship that brings academia and industry together to perform coordinated research with a budget of €1bn over ten years. This example of long-term

Bottom-up production

investment suggests a clear intent to accomplish real benefits

Bottom-up production approaches start with hydrocarbon

to society. It simultaneously highlights, however, that the

precursors and grow graphene. The most common of these

challenges are far from trivial if graphene is to successfully

methods is chemical vapour deposition (CVD)5. Large, milli-

penetrate all technological areas. Among these challenges,

metre-scale sheets can be grown and there is fine control of

large-scale sustainable production of high-quality material is

the number of atomic layers. This type of product is benefi-

near the top of the list.

cial for applications requiring high quality, large-area sheets, such as flexible transparent conductors for photovoltaic cells. A disadvantage is that the material, although high in quality,

Challenge and Opportunity

is produced in small quantities and typically requires a some-

The attractive simplicity in the story of graphene’s isola-

times complex post-production transfer step. This additional

tion has not translated to large-scale production. In order

step takes graphene off the substrate from which it was grown

to produce large quantities of graphene for industrial appli-

and moves it into the intended application.

cations, we’ve had to put away the sticky tape and consider new processing methods with the potential for high quality and high-throughput. These methods are categorised under two different production routes, summarised in Figure 3. Whether or not you choose bottom-up or top-down, depends on a number of factors, including your intended application and quality requirements. What about graphene quality? Not

In order to produce large quantities of graphene for industrial applications, we’ve had to put away the sticky tape and consider new processing methods with the potential for high quality and high-throughput

all ‘graphenes’ are the same and in fact a number of production routes lead to ‘low-quality graphene’. This is a broad

The bottom-up approach has potential to incorporate graphene

expression to cover: graphene containing more than one-layer,

into microelectronic devices also. CVD is already in use in silicon

graphene with ‘holes’ in the structure due to missing atoms, or

fabrication plants (or fabs), and an obvious path is to integrate

graphene flakes with low aspect ratio. These ‘defects’ are often

graphene into existing complementary-metal-oxide-semi-

the result of the production route. While they can be an issue

conductor (CMOS) processing techniques in this way. This also

Figure 3: The two production routes for graphene1 TOP-DOWN APPROACH

BOTTOM-UP APPROACH

GRAPHITE

HYDROCARBON PRECURSORS

PRODUCTION OF GRAPHENE

EG SOLVENT EXFOLIATION, SHEAR-INDUCED APPROACHES ELECTROCHEMICAL APPROACHES, BALL MILLING, ETC

EG CVD, EPITAXIAL GROWTH, ARC DISCHARGE

DECEMBER 2018/ JANUARY 2019 | The Chemical Engineer | page 26

graphene DG.indd 26

06/12/2018 13:37

feature graphene production

leverages significant advancements previously made by the semiconductor industry. Aside from low throughput, the major challenges here include differences in processing parameters (temperature, chemicals, catalysts) coupled with the current need to grow graphene on substrates such as copper, which is not compatible with contemporary silicon fabs.

Top-down production Top-down production approaches use a graphite precursor, and exfoliate monolayer and few-layer graphene from this 3D crystal. The aim is to overcome the weak van der Waals attractive force holding layers together and prevent them from restacking through dispersion in a suitable solvent. This is done through either mechanical, chemical, or electrochemical methods that fall under a domain known as liquid-phase exfoliation1. In general, top-down liquid-phase exfoliation offers the highest graphene production rates (lab-scale devices have reached ~10 g/h). These graphene dispersions have a distribution in both size and thickness. Due to these process characteristics, the material produced from top-down methods has already infiltrated many ‘low-hanging fruit’ applications. This includes composites and inks, where large quantities are important, and size variability is acceptable. In particular, non-oxidising mechanical and electrochemical methods produce a material with sufficient quality for most application areas. This broad applicability means top-down production is

in reach: production-scale graphene for microelectronics

a favourable route for scaleup. The following discusses a broad selection of methods that have emerged. oxide are poor compared to graphene. Thermal and chemical Mechanical exfoliation of graphene is achieved by applying

post-process steps can be used to reduce these adverse effects,

mechanical force to the layers of a graphitic crystal. Normally,

however, the resultant product (known as reduced graphene

this is done by dispersing graphite particles in a suitable

oxide, Figure 1) is usually of lower quality than that produced

solvent, and generating sufficient fluid stresses to separate

by non-oxidising mechanical and electrochemical processes.

layers of graphene within the dispersion. Ways to do this include

The production steps are generally performed in batch opera-

sonication, high-shear mixing, supercritical fluids, microflu-

tion, and the formation of toxic gases (ie NO2/N2O4) is a limiting

idisation, jet cavitation and many others. Some do not scale

characteristic.

well beyond the lab (ie sonication) whereas other processes (ie high-shear mixing) have been shown to scale up in batch

Electrochemical processes implement a graphite electrode and

operation. A lack of green solvents is a drawback, particularly

a potential difference to promote the intercalation of mole-

if we are to develop sustainable and environmentally-friendly

cules between the graphene layers. The layers are forced apart,

solutions. The most suitable solvents include N-methyl-pyrro-

separate from the bulk graphite electrode and disperse into

lidone (NMP) and dimethylformamide (DMF). These solvents

an electrolyte solution. This method avoids the use of harsh

have high boiling points, making them difficult to remove from

solvents or oxidants as in chemical exfoliation, and can achieve

applications afterwards. Aqueous-surfactant dispersions work,

some of the highest yields (up to 80%). When the graphite

and overcome these problems, however, production yields are

electrode is used as a cathode (cathodic exfoliation), the elec-

substantially lower. It also impacts quality, as it is difficult to

trochemical exfoliation potential is lower than the oxidative

remove the surfactant from the product.

potential and the product quality does not suffer from the attachment of oxidative species (unlike in the case of anodic

Chemical exfoliation relies on the conversion of graphite into

exfoliation). A disadvantage of the current electrochemical

graphite oxide using strong oxidants. Then, with an addi-

methods is in the replenishment of the graphite electrode once

tional hydrolysis step, the graphite oxide is split into graphene

spent, and unfavourable graphite breakup as this leads to a loss

oxide (see Figure 1). With attached oxygen groups and irrevers-

of electrical contact between the graphite and applied voltage

ible basal plane defects, the electronic properties of graphene

potential.

DECEMBER 2018/ JANUARY 2019 | The Chemical Engineer | page 27

graphene DG.indd 27

06/12/2018 13:37

feature manufacturing

Figure 4: process considerations for top-down graphene production1

of developmental timelines range from 2020 for composites, to beyond 2024 for areas such as graphene photonics, integration

NS

–P A – C RTI ND A R CL O N C O I – D B O E S IZ E AG ECT N E E N – R P PA NSI CON DIS TO INS ATIO T RT T Y S T C D N T I FI I C O F EN T R IBU – N N M L A ME RT TIO – B O R E T H D E F / PU R T I O N E TA NG HIP C I T P E UL H ICK C IT Y R T G -S N T K D OL E KA UC PO ME O NE S 1. AC – P R R O D A N S U R E – p ENS GY SS GR –P R P C H T I AP – TY – PR O H – NA ITE S ST N T E P O CT I O S U L . Y N R A EC 6 U SS TH L / TI OD CE ON ET PR R O : IC – SOLVENTS – QUALITY P FOR DISPERGRAPHENE ASSESSMENTS SION (LOW LARGE-SCALE – GRAPHENE BOILING POINT, PRODUCTION SEPARATION CONSIDERATIONS NON-TOXIC) 2. OTHER 2. OTHER – RECYCLE OF – SURFACTANTS FEED FEED UNUSED – TARGET GRAPHENE PRODUCT MATERIALS – LARGE SCALE CAPABILITY MATERIALS FOR DISPERSION MATERIALS (AQUEOUS – FINANCIAL FEASIBILITY – ADDITIONAL SOLUTION) – HSE/PROCESS SAFETY FUNCTION– SUSTAINABILITY – INTERCALATION ALISATION – R&D 4. E COMPOUNDS (IF REQUIRED) E X GR A H I T T IO N P FO P H A IA ME LIAT ITE G R FO L S S . 3 EX T H IO E OD N E- OC PR PR – – TS – Y M N EN T – P L AY OR IELD –P S M CT I O M EN R O – L E R O C E R D PH O S E E T L S NG A CE ES I S T LO E RE S S A G SS TH SR R T E INT /AR EP IBU Y I T Y IZ R E T P EN AL E S E E SIF A D ATA ION Q U T I C L A RY – I B S I CA I SS AR TIO TRIB LIT Y – P EC E N E UT YN NH ION N AN –A CE ME NT O ITI

When will it deliver? In a recent roadmap from the Graphene Flagship4, estimations

with CMOS and silicon photonics, high frequency electronics, and printed heterostructures. This suggests approximately 20 years from breakthrough to widespread adoption, and based on historical evidence for other technological breakthroughs, that would be a reasonably fast outcome. The future for graphene and other layered materials is promising, but a focussed effort from multiple disciplines must continue if we are to achieve this.

The future for graphene and other layered materials is promising, but a focussed effort from multiple disciplines must continue if we are to achieve this Many challenges remain. Production methods will have to be continuous, scalable, reliable and adaptable, evolving in parallel with the developmental timelines for graphene technologies noted above. Environmental and sustainability issues must also be solved when moving from lab to industrial-scale volumes. The best solvents for liquid-phase exfoliation of graphite are toxic, and the low process yields that many approaches deliver (typically less than 10%) do not help. High-fidelity measurement techniques that are used in the lab to characterise graphene materials do not scale up, and alternative quality control solutions and metrics that work in an industrial environment are needed. One thing is certain, to succeed in making high-quality graphene at scale, process

Up to now, we have focussed on methods for graphene produc-

engineering will have a central role to play.

tion. There are many more aspects of the entire process that require consideration if industrial scaleup is to be realised. These are outlined in Figure 4. Out of all the components in the

References

end-to-end process, quality assessments of the precursor and

1. Stafford, J, Patapas, A, Uzo, N, Matar, OK and Petit, C, 2018,

product, high-throughput separation, material recycling, and

“Towards Scale-up of Graphene Production via Nonoxidizing

storage and handling are particularly underdeveloped.

Liquid Exfoliation Methods”, AIChE Journal, 64(9): 3246-3276. 2. ISO/TS 80004-13:2017, 2017, Nanotechnologies - Vocabulary -

One of Many

Part 13: Graphene and Related Two-dimensional (2D) Materials. 3. Novoselov, KS, Geim, AK, Morozov, SV, Jiang, D, Zhang, Y,

Graphene is unique in the breadth of its exceptional properties,

Dubonos, SV, Grigorieva, IV and Firsov, AA, 2004, “Electric

but it’s not alone. Since its discovery, an entire field of research

Field Effect in Atomically Thin Carbon Films”, Science,

on layered materials and heterostructures (a combination of

306(5696):666-669.

dissimilar layered materials) has emerged. Other layered mate-

4. Ferrari, AC et al, 2015, “Science and Technology Roadmap

rials with impressive properties include hexagonal boron nitride

for Graphene, Related Two-dimensional Crystals, and Hybrid

(insulator), molybdenum disulfide, and black phosphorus (semi-

Systems”, Nanoscale, 7(11):4598-4810.

conductors). These are only three examples from a larger set of a

5. Zhang, Y, Zhang, L and Zhou, C, 2013, “Review of Chemical

few dozen that have been investigated so far. In fact, it has been

Vapor Deposition of Graphene and Related Applications”, Acc

predicted that there may be up to 2,000 exfoliable materials6,

Chem Res, 46(10):2329-2339.

with the possibility of them each having useful material proper-

6. Mounet, N et al, 2018, “Two-dimensional Materials from

ties. Advancements made in large-scale production techniques

High-throughput Computational Exfoliation of Experimen-

for graphene will no doubt be a benefit here.

tally Known Compounds”, Nature Nano, 13:246-252.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 28

graphene DG.indd 28

06/12/2018 13:37

feature safety

HAZZZZOP? Believe it or not, the role of HAZOP scribe has much to o er p an co in che ica en ineers CONOR CROWLEY PROCESS SAFETY TEAM LEAD (ABERDEEN), ATKINS

I

T’S NOT uncommon for engineers to end up as HAZOP

one new, I would say, don’t underestimate your role. The scribe

scribes early in their career. Far from being a straightfor-

can keep the HAZOP moving, can save a lot of time by antic-

ward secretarial functional activity, at Atkins we believe

ipating what’s coming next (and pre-populate upcoming en-

that it’s a very important role for a chemical engineer to do,

tries), and keep the facilitator on track if they miss something.

and also very important that the scribe is an engineer, and able

Once a scribe is more familiar with the way things are typically

to contribute to the meeting. I spoke to a few members of our

worded or written, they’ll be able to complete the record in a

team of scribes.

manner such that it requires little or no amendment from the facilitator.

Q: We believe that the scribe is one of the most critical roles in a HAZOP, but it is often overlooked. How would you describe the role to someone about to start it?

Aftab Ramzan (AR): I wouldn’t say scribes are overlooked – at times they get more praise than the facilitators! But to some-

Ailsa Munro (AM):

Scribes have the very important role of

capturing the discussion in the room and recording it in a clear and understandable manner. This would typically include recording the causes, consequences, effective safeguards, risk rankings and recommendations for each node reviewed during the HAZOP session. It can be a bit daunting to step into a room

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 29

crowleyscribes DG.indd 29

06/12/2018 13:35

feature safety

full of engineers and have to type up the discussion on a screen

with the design or operation. Hearing from other engineering

in front of everyone, but, in my experience, the HAZOP team

disciplines is so valuable and allows you to gain an insight into

has always helped me when I don’t know exactly how to inter-

parts of the process you aren’t usually involved with.

pret something discussed. There are also other responsibilities

HAZOPs are the perfect chance to learn from other people’s

that the scribe may have, such as: marking up nodes on P&IDs,

experiences. For example, the HAZOP team members that

making sure all required documents are available in the HAZOP

work on site or offshore can explain previous incidents or near

room, pulling up P&IDs on the screen for quick reference, and

misses they have had and what measures were implemented

writing up the end product – the HAZOP report!

to stop them from reoccurring. HAZOP chairs also have such a

Alison Thackeray (AT):

breadth of experience due to facilitating many workshops over As a scribe, it’s your responsibil-

the years and can draw on lessons learned from other clients

ity to ensure the record is populated accurately and is detailed

and assets. It is then your job to incorporate all these insights

enough so that if someone needs to revisit the HAZOP they don’t

to produce a quality HAZOP record.

need to ask questions. You need to be fully engaged, have a good understanding of the subject matter and be able to translate discussion within the room into causes, consequences, safeguards and standalone recommendations. You are also required to use your initiative to determine what discussion is vital to record and what just isn’t necessary. Don’t be afraid to ask someone to repeat a point, elaborate,

Q: So it’s a glamorous role, allowing you to travel around the world, and experience amazing places, eat great food, stay in hotels. Where has it taken you?

AR:

I’ll probably get some glaring looks from colleagues, but

or shout out a tag number. Ensure you are familiar with the risk

I’ve been to the Netherlands, Monaco, Egypt, Azerbaijan,

ranking process and the client’s risk matrix in advance of the

Oman and South Korea. And let’s not forget the more glamour-

session. Make sure any documents you may need throughout

ous locations like Aberdeen, Surrey and Leicester! There was

the HAZOP are available in the room or saved on your laptop

a close call once – I was scheduled to be in Algeria (at a sister

so you can display information on the screen, without delaying

site) at the time of the In Amenas terror attacks, but a few days

the process.

before, we were told by the client that the HAZOP was being postponed.

Q: HAZOPs are just boring, right? Why would a chemical engineer want to take part in one, especially just as a scribe?

AR:

AT:

So far, scribing has taken me to Azerbaijan and Brazil as

well as locations all around the UK. I love travelling with work and seeing new places plus it’s great to get out of the office,

It’s a great way to learn about new processes, new sites

speak to clients, grow your network and get involved with

or even a new industry. I’ve been lucky in the fact that I’ve

their projects. Baku probably isn’t somewhere I would have

managed to scribe at a number of surface gas and drilling fluid

ever have visited for a holiday, but I had a great time exploring

handling systems HAZOPs, which has given me a platform to

the city (when I wasn’t working extremely hard). Our client in

(hopefully) facilitate some of them one day. HAZOPs also give

Brazil also took us for lunch on the beach on our last day of the

you the chance to meet a number of different people from

workshop and I thought: “I could definitely get used to this!”

different backgrounds, and mix with other engineers. You also hear some great stories from the HAZOP team members.

AM:

AM:

I have ventured as far as six miles from the office for a

HAZOP. Not that I am jealous of the others at all. I still had Well, I would have to say that one of the most interesting

good food and the comfort of my own bed at night.

projects I have worked on so far has involved a three-month stint of HAZOP scribing! It gave me the opportunity to learn a lot about the upstream oil & gas process, from wellheads to compressor auxiliaries, flare systems to produced water systems, and many other critical process systems in between. You

Q: One of the key roles of the scribe is to support the chair, but they’re all so different. How do you approach that?

also get to meet people from different disciplines and people

AR: You can get a feel for the facilitator fairly quickly, particu-

who have worked in different sectors who can bring interesting

larly if you’ve met them beforehand. I’ve found some facilitators

stories to the table.

are pernickety, and others give you a free rein. Essentially, as

AT: Personally, I don’t find HAZOPs boring at all, it only becomes boring if you don’t participate. You can learn a lot from taking

long as you’re paying attention and are completing the HAZOP record, they won’t mind.

part or scribing at a HAZOP. Every process is different, and the

AM:

HAZOP team always talks through the process and dissects it

understand what they expect from the scribe before, during

to ensure we have determined all potential failures or problems

and after the session. This might mean gathering together

It is best to meet with the chair before the HAZOP to

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 30

crowleyscribes DG.indd 30

06/12/2018 13:35

feature safety

Doing the write thing: (L–R) scribes aftab ramzan, Ailsa munro, Alison thackeray

worksheet templates, documents, drawings and an attendance

especially when software updates mean that your laptop takes

register in preparation for the HAZOP. During the session, you

an excruciating amount of time to load up when the whole team

generally get a feel for when the discussion should be captured

is sitting around waiting to start.

and what terminology to use in the record. Don’t be afraid to keep the chair on track if you need to, of course.

AT:

AT:

Yes, unfortunately spelling errors happen occasionally,

but sometimes they do give people a good laugh. People do I always have a conversation with the chair prior to the

tend to fall asleep occasionally, especially after lunchtime. It

HAZOP to determine their hosting style, what sort of input they

is definitely a challenge for the HAZOP chair to keep everyone

want from the scribe and generally to ensure we are prepared

motivated and engaged for the duration of the exercise.

for the workshop. Some chairs like you to wait until a decision has been reached by the team before you record information, when others like you to take the lead and capture the discussion in a coherent manner and create recommendations based on what you gauge from the room.

AR:

Q: Would you want to be a HAZOP chair? What would you do differently? I am looking to become a facilitator and have started to

Regardless of their style, you just need to ensure that you are

co-facilitate a few workshops, so fingers crossed, the opportu-

engaged throughout the day and help the chair as much as you

nities present themselves so that I gain the relevant experience.

can. Trying to stay ahead of the curve really helps any type of

Having scribed for different facilitators, I’ve picked up little

chair and the progress of the workshop. If the chair has to pause

tips here and there, like how to subtly take control of the room,

the discussion and help populate or amend the HAZOP record,

but I guess I won’t know what I would change until I’m thrown

the team can become distracted and you lose valuable time.

in at the deep end. I once heard that a HAZOP facilitator fell asleep on the second day of a weeklong study, so as long as I

Q: Any HAZOP mistakes you’d like to share with us?

AR:

I was told before my first HAZOP that I can’t be as bad as

don’t do that...

AM:

I wouldn’t rule out taking on the HAZOP chair role in the

a (more senior) colleague, who deleted an entire floppy disc’s

future. All of my HAZOP experiences so far have been enjoyable,

worth of work at the end of his first day!

and the teams have worked well together. However, I imagine

I remember an instance where a process engineer didn’t

it is a lot more challenging to facilitate and keep the motiva-

turn up (the HAZOP couldn’t go ahead without them), so the

tion up for larger teams or teams that do not agree on certain

company vice-president ended up getting a call at 2 am (his

details. I am not sure what I would change, but I think making

time) asking for someone else to be sent along. Oh, not to

sure that everyone in the room feels they can get involved is

mention that time I wrote the word “pimp” instead of “pump”!

key.

AM:

Spelling other HAZOP team members’ names wrong

AT: At the moment I am not thinking that far in advance. I have

in front of the whole room is always dangerous. My name is

only been with the company for three years, so I am trying to

often spelt incorrectly, so I like to get other people’s right. I

gain as much experience as I can and then my next goal will

haven’t been fully successful on that front, but I am grateful

be to meet the requirements to become a Chartered Engineer.

it was received with a laugh! Technology can also be an issue,

Maybe in the future, who knows!

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 31

crowleyscribes DG.indd 31

06/12/2018 13:35

feature safety

Managing ALARP in Major Engineering Projects How to identify threats and achieve ALARP on a big scale CLAUDE LABRIE; CHRISTINA PHANG HSE PERFORMANCE MANAGER, BW OFFSHORE; PRINCIPAL PARTNER, ERM

T

HE principle of reducing major accident risks to levels

PRINCIPLES OF ALARP

that are as low as reasonably practicable (ALARP)

The principle of ALARP applies to risks that are, first and

is now typically embedded in the risk acceptability

foremost, assessed to fall within tolerable limits. This concept

criteria specified for the engineering, construction and opera-

is illustrated in Figure 1 where tolerability limits are typically

tion of installations presenting major accident hazards.

defined in terms of individual risk per annum (IRPA). Risk

The principle, although essential in promoting safety

tolerability and the distinction between risks that fall within

improvements, introduces scoping and execution uncertain-

the ALARP region and risks that are tolerable are well docu-

ties with potential impacts on costs and schedule of major

mented1 and therefore not the subject of this article, though we

capital projects. Applying ALARP successfully is closely linked

note that that risk levels lying within the ALARP region are still

to the stages of the engineering lifecycle and the associated

occasionally misinterpreted as representing acceptable risk

contracting strategy, and to fundamental factors of percep-

levels or risk levels that are ALARP. Risk estimates within the

tion, leadership, ownership and communication. We’ll examine

ALARP region of any risk tolerability framework should only be

these links here to identify possible threats and management

deemed as acceptable or tolerable once it is demonstrated that

measures to deliver installations presenting major accident

all reasonably practicable risk reduction measures have been

risks that can be demonstrated as ALARP.

implemented.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 32

ALARP DG.indd 32

05/12/2018 13:51

feature safety

Figure 1: Typical Representation of ALARP Region UNACCEPTABLE REGION

RISK CANNOT BE JUSTIFIED SAVE IN EXTRAORDINARY CIRCUMSTANCES TOLERABLE ONLY IF RISK REDUCTION IS IMPRACTICABLE OR IF ITS COST GROSSLY DISPROPORTIONATE TO THE IMPROVEMENT GAINED

THE ALARP OR TOLERABILITY REGION (RISK IS UNDERTAKEN ONLY IF A BENEFIT IS DESIRED)

•

detection and control (limitation of scale, intensity and duration);

•

mitigation of consequences (protection from effects); and

•

escape, evacuation and rescue arrangements.

Typically, major accident hazards are managed by a combination of the means listed above. Hazards inherent to the existential function of the facilities (eg producing hydrocarbons) cannot be completely eliminated, such that residual risks

TOLERABLE IF COST OF REDUCTION WOULD EXCEED THE IMPROVEMENT GAINED

that remain after the consideration of inherent safety and prevention invariably need to be managed by a combination of control, mitigation and emergency response arrangements.

NECESSARY TO MAINTAIN ASSURANCE THAT RISK REMAINS AT THIS LEVEL

BROADLY ACCEPTABLE REGION (NO NEED FOR DETAILED WORKING TO DEMONSTRATE ALARP)

The design intent should be to reduce dependence on the latter three considerations as far as reasonably practicable to achieve comparable or superior safety levels. Another hierarchy of risk management preferences not captured explicitly above, but linked to inherent safety is as

NEGLIGIBLE RISK

In an engineering context, the following tenets are applied to ensure that the HSE risks associated with the operations of a

follows: •

engineered passive measures (eg fire proofing);

•

engineered active measures (eg firewater deluge); and

•

administrative or procedural measures (eg manual firefighting).

hazardous installation are ultimately ALARP: Even in the context of hazard control and mitigation, the •

gain a good understanding of the hazards;

inherent safety mechanism of simplicity applies, and prefer-

•

apply a hazard management hierarchy, giving priority to

ence is to rely on passive systems that do not depend on the

inherent safety;

availability of complex functions such as power supplies, where

•

implement recognised good practice;

possible or practicable. Similarly, preference is given to fail-

•

consider ALARP in the selection of design options; and

safe safety functions over those that depend on the availability

•

consider risk reduction measures.

of power or control signals. Again, major accident hazards are

Understanding Hazards

commonly managed by a combination of complementary engineering and procedural measures, but the design intent should

Systematic hazard identification methods including HAZID and

remain to rely as far as practicable on passive means to achieve

ENVID are applied to identify safety, health and environmental

comparable or superior safety levels.

hazards associated with a major hazard installation, and each of the hazards identified is assessed to a level commensurate to

Recognised Good Practice

the associated perceived risks and with increasing details and

Recognised good practice defined in terms of recent past experi-

refinements as the design of the facilities progresses.

ence, codes and standards is typically an important instrument

Hierarchies of Means of Hazard Management

to achieving ALARP. This is illustrated in the Oil & Gas UK decision-making framework 2 shown in Figure 2. When the decision

An inherently safer design is achieved by eliminating hazards,

context is common and well understood, codes and standards

or reducing the likelihood of occurrence or the severity of

recognised as representing good practice can be relied upon

the potential consequences of their manifestations by careful

to achieve risks that are ALARP, supplemented by risk assess-

attention to the fundamental design or layout. Mechanisms

ments and detailed studies when the context deviates from the

typically associated with inherent safety are minimisation,

normal application or when alternative options have signifi-

substitution, moderation and simplification.

cant economic implications.

The widely-accepted hazard management hierarchy applied in designing hazardous installations is given below:

ALARP Support of Design Decisions Design decisions with significant impact on the safety of

• •

elimination and minimisation by design (inherently

personnel should be supported with due consideration of

safer design);

safety. Such decisions include the selection of process scheme

prevention (reduction of likelihood of occurrence);

options, equipment technology options, equipment redundancy

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 33

ALARP DG.indd 33

05/12/2018 13:51

feature safety

Decision Context

Figure 2: Risk-Related Decision Making Framework Factor

A

B

C

Type of Activity

Nothing new or unusual. Represents normal business. Well-understood activity. Good practice well-defined.

New to the organisation or geographical area. Infrequent or non-standard activity. Good practice not well defined or met by more than one option.

New and unproven invention, design, development or application. Prototype or first use. No established good practice for whole activity.

Risks are well understood. Uncertainty is minimal.

Risks amenable to assessment using well-established data and methods. Some uncertainty.

Significant uncertainty in risk. Data or assessment methodologies unproven. No consensus amongst subject matter experts.

No conflict with company values. No partner interest. No significant media interest.

No conflict with company values. Some partner interest. Some person may object. May attract local media attention.

Potential conflict with company values. Significant partner interest. Pressure groups likely to object. Likelihood of adverse attention from national and international media.

Risk and Uncertainty

Assessment Technique

stakeholder influence

Good practice engineering risk assessment precautionary approach

levels and equipment locations, and decisions that may not

measures can be supported by engineering rationalisation and

arise from formal study actions or recommendations. Tracea-

judgement, references to current best practice and cost-bene-

bility of such decisions can be challenging, and all disciplines

fit analysis if required. The UK Health and Safety Executive has

and project management have a role in appreciating the safety

published comprehensive guidance on the ALARP decisions and

impact of design decisions.

demonstration in a suite of web pages3.

Management of change processes should consider the requirement to demonstrate that changes result in risks that

Demonstrating ALARP

are ALARP, particularly when changes impact or conflict with

Demonstration of ALARP is the culmination of the risk manage-

decisions made in previous engineering phases.

ment and risk reduction efforts described above, justifying

Consideration of Risk Reduction Measures A design environment conducive to identifying and consid-

continued design development or operation of the installation. Demonstration of ALARP should be clearly documented as part of a safety case of the delivered assets.

ering risk reduction measures should be established to allow engineering disciplines and stakeholders to raise ideas. The main source of risk reduction measures formally recorded for

EXECUTION OF MAJOR CAPITAL PROJECTS

due consideration, however, arise from HSE study actions and

Major capital projects (typically >US$500m) in the oil and gas

recommendations, and from ALARP workshops dedicated to

industry are executed in phases as shown in Figure 3. Though

identifying risk reduction measures based on a documented

terminology may differ between owners, projects start with

appreciation of the risks and their drivers.

conceptual phases where business potentials are appraised and

All such ideas, actions and recommendations should be

where development solutions are compared and selected. These

formally addressed and closed out in a traceable manner to

are the stages when the decisions defining the fundamental

support the demonstration of ALARP. Depending on the poten-

inherent safety of the project installations are taken. Concept

tial risk benefits and associated net costs (or effort or sacrifice)

selection is then followed by some form of basic engineering or

of implementation, the implementation (or not) of risk reduction

front end engineering design (FEED) phase when the project scope

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 34

ALARP DG.indd 34

05/12/2018 13:51

feature safety

Figure 3: Project Phases and ALARP Decisions Project Phases Appraise

GATE Select

GATE define

FID

rfsu

execute

front-end loading engineering stages

construction procurement detailed design

options identification

concept selection

alarp decisions (examples) - Green or brown field

- Green field

- Dry or subsea trees

- Subsea trees

- Pipeline or FSO

- FPSO

- Integrated platform

- Gas export pipeline

- Multiple platforms

- Gas lift/water injection

• A/UP/D • AU/PD • A/UPD - FPSO - MOPU

feed - Bow or stem LQ - Internal or external turret - Electrical motor or turbine drivers - Process scheme - Sparing of main machinery - Modules layout - Fire/blast walls - Type of TEMPSC - Fire protection philosophy

-

Additional process segregation by SDVs Blowdown rates and PFP optimisation Addition of oil mist and acoustic leak detection Minimisation of leak paths on greatest risk contributors Selection of seals on HC liquid pumps Segregation of pool fire areas by deck coaming Improved fire ratings Selection of extinguishing agent Review of gas alarm settings Finalisation of blast resistance requirements Optimisation of PFP coverage Maximisation of use of gratings for natural ventilation Addition of elevated escape routes across top decks of modules

and planning are defined to support a final investment decision

design envelope within which the principles of ALARP are to be

(FID). Inherent safety still represents an effective mechanism of

applied.

risk management during FEED when the process schemes and

If a concept selected does not present risks that are ALARP, then

layouts are developed. It is during FEED that the control and miti-

the FEED of the same concept will equally not present risks that

gation philosophies are outlined and developed to manage the

are ALARP, though they may be at ALARP levels with reference to

residual risks. Upon FID, project execution starts with detailing

the concept selected. Unless specified otherwise, the perception

of the design to support scheduled procurement, construction and

of the engineering contractor will be that the design basis handed

commissioning activities. Given robust front-end loading (FEL)

over for further development presents risks that already meet the

in the engineering process, risk reduction during detailed design

ALARP concept, and their requirement to deliver risks that are

may be limited to ALARP decisions arising in the specification of

ALARP refers to the design basis.

performance requirements for previously established safeguards.

The same situation can apply when a FEED is handed over

A typical project contracting strategy is to award a FEED

for project execution. If the FEED does not present risks that are

contract executed on a cost reimbursable, or cost-Plus fee (CPF),

ALARP, then the design implementation will equally not present

basis, followed by lump sum/fixed price (LSFP) contracts for engi-

risks that are ALARP. Although some form of FEED validation or

neering, procurement and construction (EPC)4.

verification process is typically imposed on the EPC contractor

As design delays and changes can be very disruptive under a

for endorsement of the design basis, the resources and potential

LSFP EPC contract, it is recognised that a high-quality FEED with

returns of the process are generally such that ALARP status of

robust FEL is a pre-requisite to successful project execution5.

working solutions will not be questioned. On a project with robust FEL, a range of fundamentally different

HANDOVER OF ALARP AT PROJECT PHASES

but workable concepts could be considered, and concept selection would be supported with assurance that tolerable risk levels can

The requirement to deliver a design presenting major accident

be achieved, and with a demonstration that the cost of any inher-

risks to personnel that are ALARP is typically specified in FEED

ently safer concept is grossly disproportionate to the potential risk

and EPC contracts. However, what is less explicitly stated is the

benefits. The FEED will normally be supported by a design safety

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 35

ALARP DG.indd 35

05/12/2018 13:51

feature safety

case including a demonstration of ALARP addressing a compre-

considerations may be viewed as additional cost or schedule

hensive set of design decisions and potential risk reduction

implications.

measures, establishing a well-defined risk management strategy

Effective implementation of the ALARP principle requires a holistic perception of how it supports the project, taking

for implementation. Additional major accident risks resulting from handover of a

into account viewpoints of personnel who will ultimately be

concept that is not ALARP for FEED is strictly borne by the asset

exposed to the major accident hazards, and an appreciation

owner, more specifically by the personnel that will be exposed to

that personnel safety benefits resulting from the application of

major accident hazards. The FEED contractor would not normally

the principle normally entail benefits in terms of asset, repu-

be required to question the concept selected, and the cost impli-

tation and environmental risks. Project deliverables presenting

cations of any change to the design at that stage of engineering

risks that are ALARP benefit all stakeholders, such that the

is generally limited to engineering man-hours, which are often

ALARP principle should be perceived positively.

reimbursable.

Leadership

More challenging is the handover of a FEED that is either insufficiently developed or not ALARP for EPC. Unplanned

Strong leadership from the top is essential for effective imple-

design developments and changes during EPC can have signifi-

mentation of the ALARP principle, particularly where the

cant procurement and scheduling cost implications. If the owner

relevant regulatory authority neither embraces nor imposes

strictly imposes the contractual ALARP principle in this context,

the ALARP principle.

the costs of ALARP decisions can seriously disrupt project execu-

Owner or duty-holder project management must actively

tion. Worse still, smooth project execution can unduly tax the

promote the application of ALARP values. Without this lead-

application of ALARP values by considering the costs of project

ership, the project would rely on the engineering contractors

disruption in ALARP decisions, and the added risk again falls on

to document design decisions and consider potential risk

the personnel that will ultimately be exposed to the hazardous

reduction measures. Although engineering contractors may

effects.

be contractually required to do so, it is conceivable that nonALARP working solutions could go unchallenged if the project

FUNDAMENTAL SUCCESS FACTORS

performance criteria are heavily biased on execution schedule. In conceptual design, FEED and detailed design, project

A successful application of the ALARP principle is one where

and engineering managers have key roles in promoting the

the risks to personnel can convincingly be demonstrated to

due consideration of safer design options and risk reduction

be ALARP. It is one where the major accident hazards are well

measures. Engineering managers have the key roles of recog-

understood, where design options are weighed with due consid-

nising design decisions with significant impact on safety and

eration of safety, where good practices are applied, and where

promoting safety by design across all discipline, with support

risk reduction measures are considered in a timely manner. It is

from the process safety discipline. Without project manage-

one where ALARP values are applied in all design development

ment leadership, the process safety discipline would unlikely

phases, front-loading ALARP considerations where possible to

be effective in performing these roles.

minimise disruption of the engineering process and maximise

Projects should not rely too heavily on formal safety assessment consultants to identify potential risk reduction measures.

the practicability. There are many factors that contribute to the successful

Expectations should not be that the safety consultants will

application of the ALARP principle including the risk assess-

make all the risk reduction recommendations required to effec-

ment methodologies applied, the value of resources used and

tively demonstrate that major accident risks are ALARP. Safety

the decision-making process applied, but fundamentally,

consultants have different clients with requirements that do not

success is considered to be mostly dependent on basic elements

always align and may give rise to conflict of interest. They have

of perception, leadership, ownership and communication.

too much invested in future opportunities to suggest, without

Perception

inducement, design changes that could have a cost or schedule impact on their direct clients. For effective input of the formal

The lack of priority or ineffective application of ALARP values

safety assessment into the ALARP process, adequate resources

may fundamentally be attributed to negative or biased percep-

must be allocated for the clear presentation of risk drivers and

tions of the ALARP principle itself. For stakeholders that seek

for the conduct of sensitivity studies, and owner and engineer-

the benefit of rapid execution, ALARP considerations may be

ing contractors are required to question risk results and key

considered as unnecessary distractions; solutions that have

contributors to support the formulation of recommendations.

worked in the past need not be questioned. For engineering resources that are only exposed to the ALARP principle

Ownership

in the context of formal safety assessment, it may be viewed

The scenario to avoid is the unchecked handover of ALARP

as a risk assessment outcome that is subject to specialist

requirements from the owner to engineering contractors, and

consultant interpretation. For a lump sum contractor, ALARP

from engineering contractors to safety consultants.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 36

ALARP DG.indd 36

05/12/2018 13:51

feature safety

The owner and engineering contractors are responsible for the

phases are good opportunities to establish this understanding

ALARP status of the decisions they each make, but the owner or

and clarify expectations.

duty-holder has overall accountability for the delivery of facilities presenting risks that are ALARP. The owner or duty-holder is therefore responsible for providing adequate resources to

CONCLUSIONS

achieve risks that are ALARP, and for communicating and facil-

The principle of ALARP must be applied from the onset of the

itating the application of ALARP values.

engineering lifecycle to deliver facilities presenting major

Formal safety assessment consultants can only advise,

accident risks that are truly ALARP. EPC implementation of

support and assist in demonstrating that risks are ALARP. As

a concept selection or FEED that does not present risks that

described above, ALARP tenets should include the support of

are already ALARP cannot be expected to present risks that

design decisions and the application of good practice, aspects

can be demonstrated as ALARP. At best in such a context, EPC

that may not be explicitly addressed in formal safety assess-

implementation can be demonstrated as ALARP in relation to

ment. Accordingly, formal safety assessment outcomes alone

the concept and FEED information embedded in the detailed

do not demonstrate ALARP. Safety consultants feed into the due

engineering design basis.

appreciation of the hazards and may facilitate the identification

Front loading of ALARP consideration is essential to

of potential risk reduction measures, but the implementation

achieving risks that are truly ALARP as the FEED contractual

decision needs to be taken by the engineering contractor or

environment is more conducive to the consideration of risk

owner/duty-holder.

reduction schemes. Furthermore, FEED decisions have a much

It is suggested that preparation of the demonstration

greater impact on the magnitude of risks than detailing deci-

of ALARP for a given project scope remains with the party

sions. Accordingly, greater focus should be attributed to ALARP

responsible for achieving risks that are ALARP and therefore

demonstration during FEED than during EPC.

not be subcontracted out to a safety consultant. Consultants

The application of the ALARP principle in selecting design

and technical report writers can be involved, but maintain-

options and considering risk reduction measures is generally

ing direct and significant involvement in the documentation of

straightforward. Most decisions can be supported by reference

ALARP can reinforce ownership and accordingly motivate the

to best practice and rationalisation considering pros and cons.

due gathering of building blocks that will ultimately feed into

There are typically few decisions that require detailed quanti-

the demonstration of ALARP.

fied risk assessment and cost-benefit analysis for support. The

In some jurisdictions, ownership of the risk tolerability

main challenge with the application of the ALARP concept is

criteria is an issue. When the owner and relevant regulatory

the due and explicit consideration of safety in design decisions,

authority do not provide guidance on the criteria to apply, the

and the timely and traceable consideration of risk reduction

definition of the tolerability criteria is sometimes left to the

measures. Accordingly, key success factors are more fundamen-

formal safety assessment consultant, and the tendency is to

tal than risk assessment methodologies or the decision-making

rely on deterministic impairment frequency targets such as the

process applied. The success factors for delivering facilities

10-4/year impairment frequency as if they override the ALARP

presenting major accident risk levels that can be demon-

principle. Despite how frequency targets are interpreted, it is

strated as ALARP are: a positive perception of ALARP from all

important for the owner or duty-holder to take ownership of

stakeholders; ownership of the risk acceptability criteria and

the risk criteria and clearly interpret ALARP expectations for

of design decisions; leadership from the duty-holder and top

the safety of its own workforce at risk.

management levels for all stakeholders; and the clear commu-

Communication

nication of the ALARP goal and achievement approach.

Outside of project management and process safety disciplines, the principle of ALARP often remains a vague concept which

REFERENCES

is detached from the engineering process driven by a design

1. Reducing Risks, Protecting People, HSE’s Decision-making Process,

premise defined in terms of client requirements and appli-

UK Health and Safety Executive, 2001

cable codes and standards. But in reality, the design premise

2. Guidance of Risk-Related Decision Making, Oil & Gas UK, Issue

normally allows for multiple if not an infinite number of

2, 2014

working solutions, each with pros and cons in terms of safety.

3. ALARP Suite of Guidance, UK Health and Safety Executive,

All engineering disciplines can contribute to the reduction of

www.hse.gov.uk/risk/expert.htm, 2014

risks to ALARP, and it is accordingly important to clearly estab-

4. “Developing Contracting Strategies for Capital Projects

lish a common understanding of the principle and of the values

– Experiences from the Oil and Gas Industries”, TC (Kees)

to be applied in order to achieve risks that are ALARP, and

Berends, Proceedings of the sixth annual conference of European

establish a relation between the disciplines and process safety

Decision Sciences Institute, 2015

support in this context. Town hall and engineering leadership

5. Lessons Learned from UKCS Oil and Gas Projects 2011–2016, UK

meetings taking place at the start of the various engineering

Oil & Gas Authority, 2017

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 37

ALARP DG.indd 37

05/12/2018 13:51

feature process automation & control

Switching Off h operators t rn a ance contro s o (and how to prevent them from doing so) HOWARD BODER CONSULTANT, NEWLAND CONTROL

T

HIS article focuses on multivariable predictive control,

As an advanced process control (APC) engineer myself, I share

which has become the standard algorithm for advanced

the frustration that engineers feel when an APC that they have

control in many process industries. You’ll currently

worked so hard to get on control is switched off some time

find it applied in sectors from refining and petrochemicals

later. Often there are genuine reasons why this happens. To get

(where it is typically used in larger applications to control

the maximum utilisation and benefits from advanced control

and optimise a whole unit) to smaller applications in the food

applications, it is a good thing to know why operators turn

industry (where it might control a smaller unit such as a dryer

control schemes off that presumably worked when they were

or an evaporator).

first commissioned.

Multivariable control has the advantage that it is very flexible

We’ll go through the main reasons why a multivariable

and can control a process from small to large and optimise it

control scheme is switched off, and how these problems can

at the same time. The benefits of advanced control are well

be addressed.

accepted by most process industries today. By controlling key variables, and reducing their standard deviation, you can shift the mean of key variables towards their constraint, pushing the

APC doesn’t work

unit and ‘riding’ the (changing) constraints for the optimum

On most sites, operators have the ultimate say, and can switch

operation. A computer can perform this every minute, 24 hours

off an advanced control either because it doesn’t work or at

a day, outperforming even the best process operator.

least it doesn’t work how they would like it to work.

A good analogy is cruise control on a car which can hold the

Sometimes the reason that is doesn’t work is of their own

speed of a car to almost exactly the desired speed in light of

doing but they do not realise that they have made changes that

disturbances.

have caused problems.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 38

boder DG.indd 38

06/12/2018 13:30

feature process automation & control

Figure 1: Advanced control Benefits

After advanced control has been implemented,

1.2 1 MEASUREMENT

PROFIT

LIMIT

the variation has been reduced (shown in red). There is then a further

0.8

opportunity to shift the

0.6

closer to the limit (shown

average measurement in green) which increases the unit profitability.

0.4

Shifting the mean value towards a constraint is

0.2 BEFORE

0 0

VARIATION REDUCTION

50

100

150

the classic benefit that is

MOVED TOWARDS LIMIT 200

250

300

associated with advanced control

TIME

If it doesn’t work (for whatever reason), then the APC engineer

the constraints (controlled variables) which might include key

needs to troubleshoot and fix it. On one occasion, I was called

product analyses, unit temperature limits, safety limits, valve

in to look at a large optimisation scheme on a FCC (fluidised

limits, and delta pressure limits (used to indicate flooding) etc.

catalytic cracker) on an oil refinery with a number of control-

This is the most common issue that I’ve seen with multivar-

lers; the reactor, regenerator, debutaniser, and a number of

iable controllers. I’ve seen it replicated in oil refining (as in the

other light ends distillation units, all running under an opti-

above example) and in petrochemicals units.

miser. The optimiser had been switched off and left off for

Figure 2 shows a simple example of a distillation column

quite a while. It turned out that nearly all of the basic control-

with two key operator handles (top temperature and bottom

lers were constrained so there were no degrees of freedom

reboiler flow).

left for optimisation. The operators had (gradually over time)

Figure 3 shows that shrinking the operating window by

clamped most of the low and high limits of the flows, temper-

putting in tight limits on the manipulated variables (MVs)

atures and pressures (manipulated variables) and also many of

reduces the scope for optimisation. Good training and discipline is needed for operators to resist the temptation to clamp manipulated variables. By clamping

Figure 2: Distillation column operating region

MAX TOP TEMPERATURE

• THE MOST PROFIT (USING A LP) IS AT A CORNER • 2X2 = 4 POSSIBILITIES (4 CORNERS) • 2 ‘DEGREES OF FREEDOM’

Figure 3: shrinking the operating window • IF YOU OVER CLAMP THE MVS THEN YOU SHRINK THE OPERATING WINDOW • SCOPE FOR OPTIMISATION IS ALMOST GONE

MAX TOP TEMPERATURE MAX REBOILER FLOW

A linear program is used in the advanced controller to

tively reverting to a kind of ‘setpoint control’ and preventing

MIN REBOILER FLOW

MAX REBOILER FLOW

MIN REBOILER FLOW MIN TOP TEMPERATURE

in the manipulated (and controlled) variables they are effec-

MIN TOP TEMPERATURE

find the most profitable operating point, which will be in a corner. A wide operating window allows the best optimisation solution to be found within the constraints.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 39

boder DG.indd 39

06/12/2018 13:30

feature process automation & control

Operators don’t understand how it works

the advanced control from having any manoeuvrability. We will now examine the main reasons why APC may get switched off.

Whilst some operator training is often carried out as part of a good APC project, these days, this might not be very comprehensive. In the best situation, operators are taken out of the shift system for a training day where they are properly trained

Key Constraint is missing

in how to get the most out of APC using a process simulator,

It may be that a key constraint (from an operations perspec-

usually running in a standalone computer.

tive) is missing. It may have been missing from the start or

It is quite reasonable that if the operators don’t know how

it could be a new variable that has become a constraint. It is

the APC scheme works, then they would switch it off. They

important to consult the operations team during the design of

should have been trained as part of the commissioning process

advanced controls so that they share the ownership of the APC

but if a shift is accidentally missed out then they have a legiti-

solution that is developed. It might also be that the APC moves

mate reason to switch off the APC.

a combination of manipulated variables to relieve a constraint

I have been to sites where a new operator has come onto

that they do not like. Perhaps the APC is doing the right thing

shift who has not seen the APC before. They might have been

(and it’s more of a training issue) or it might be that the APC

off for a long break and missed the training or they might be

needs some ‘know how’ built into it (for instance the priority

new to working on the panel, having spent most of their time

of moves or the priority of constraints) that might need adjust-

on the outside unit.

ing based on operator experience or objectives that might have

Either way, the engineer who is commissioning the APC should have a list of all the operators and shifts that they need

changed over time. During the functional design of an application, one of the

to train in order to ensure that all shifts are up to speed with the

key parts of the design procedure should be to sit down with

new application. In this case, we have a fairly simple problem

a number of shift operators and go through how they run the

to solve. It is a training issue. There are two main options for

unit (in manual), which manipulated variables they use, which

operator training:

constraints they monitor, and what they do to relieve those •

constraints.

At-the-panel training. The engineer sits at the panel when the operator is on shift and explains to them how

It can also be the case that a model is wrong or missing from

the APC works, how to switch it on and off, change

the matrix.

constraint limits, drop non-critical variables etc,

Multivariable controllers are based on a dynamic matrix of manipulated (and disturbance) variables against controlled

working their way through all of the shifts and all of

variables (constraints)

the shift operators. Sometimes a new operator comes on shift who never went through the training when the

A typical small matrix is shown in Figure 4. Wherever there

application was first put on control and so missed the

is a relationship between variables, a model should be present.

training. Or an outside operator who normally does not

Perhaps a model has been missed out? This might give poor

work on the panel is called in for some reason to provide

controller performance.

cover and has not yet been exposed to the APC. These too need training. •

Figure4: wrong or missing model MV1

MV2

Classroom training. A (typically) one-day session in a classroom using a combination of presentations

MV3

DV1

and practicals (using process simulations, preferably including some of the operators’ actual units). It is a great way to train operators and a great supplement rather than a substitute for training at the panel.

CV1

CV2

MISSING MODEL HERE?

Wrong Model/Model is out of sync with the process dynamics Given time, a model may drift. When the model was originally identified, it may have been correct, but over time, the process may have changed. For instance, the unit may be running at a different feed rate and the model dynamics may be sufficiently

CV3

different to cause some degradation in the model quality to the extent that the model does not work well enough for the operator’s satisfaction. It is important to always do a sanity check on models to check that they make sense from a process

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 40

boder DG.indd 40

06/12/2018 13:30

feature process automation & control

it enters the nonlinear region, it does not perform as well. In

Figure5: prediction error

this case, it may need careful tuning to cope with the nonlin-

CV MODEL

ear region (compromise tuning) or else a more sophisticated nonlinear transform might be needed to enable good performance across the operation range. PREDICTION

Wrong optimisation The optimisation case for a controller is normally set up as a

ACTUAL MEASURED TIME

linear program (LP) or a quadratic program (QP). It is important to set the optimisation up correctly or else the controller will push to the wrong constraints.

point of view and not to just trust the results that are obtained

Controller too cumbersome

from a computer identifier package. A computer package can

It is well accepted that it is easier to step test, commission and

statistically derive a model that is ‘incorrect’ for a number of

maintain smaller controllers than larger controllers. When a

reasons, for example, where gains for mass in and mass out do

problem occurs there is a tendency for the operators to switch

not perfectly mass balance properly (due to meter errors).

the entire controller off. They will not always take the trouble

In Figure 5, the multivariable controller’s performance is

to isolate a problem and keep the rest of the controller running.

very much dependent on the quality of the models. The actual

A large controller with many variables is more likely to be

measured value needs to coincide reasonably well with the

switched off (unnecessarily) than a smaller controller.

prediction. If there is a large difference in the magnitude of the

Some multivariable control packages allow ‘sub controllers’

changes (gain) or in the dynamics (deadtime and lag) then the

to be set up to break up a large control problem into smaller

performance of the controller may be reduced.

chunks.

Wrong Tuning

Lack of maintenance

The tuning of a multivariable controller will affect the perfor-

Many of the above factors can be summed up as lack of main-

mance. This is especially true of the key tuning on the controlled

tenance of the application. Good maintenance for advanced

variables (CVs) and the manipulated variables (MVs). In the

control is essential for continued good performance. The

case of the CVs, multivariable control packages have weight-

tuning, performance and particularly the model quality needs

ings to set the priority of the CVs so that the most important

to be monitored, with adjustments made over time. There are

CVs are controlled in the situation where there are insufficient

some automated tools for this such as automatic step testing

degrees of freedom to control everything. These weightings

tools that carry out a partial re-step if a model drifts too far

have to be set correctly. In the case of the MVs, there are also

off. Commercial multivariable controllers can tolerate a certain

often weightings to preferentially use some MVs for control and

amount of model error but control performance does suffer as

others for optimisation and/or to reduce the movement of some

the model match with the process drifts further apart.

MVs which should not move too much nor too fast. Careful setup of the tuning is therefore very important.

Inferentials

Doesn’t make their life easier Any good APC scheme should make the operator’s life easier by taking care of the control of a part or whole of a process unit. If

Many multivariable controllers make use of soft sensors or

an APC does not really help run the unit better, then it is likely

‘inferentials’ to infer key product qualities. Very often, devel-

that the operators will switch it off.

oping good (and representative) inferentials is very important to developing a good controller if these inferentials are key constraints on the unit.

Nonlinear

Prefer to do it themselves (don’t like cruise control) I’ve sometimes seen operators switch off an advanced control simply because they prefer to run the unit themselves,

If the controller is running a unit which experiences noticeable

changing setpoints and observing how the process responds

nonlinearity within the normal range of operation, then it may

‘in manual’. Cruise control on a car is a good analogy. Whilst

be that the controller works well some of the time, but when

we might understand this (some people don’t like using cruise

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 41

boder DG.indd 41

06/12/2018 13:30

feature process automation & control

control because they prefer to ‘drive’), it is clear that on a clear motorway with little traffic, it controls the speed more accurately than a human (and reduces the risk of speeding). By setting the speed close to the maximum (for example 69 mph on a 70 mph motorway) the driver can get close to the

the other. The first school of thought is to give the operators the ability to change CV and MV limits, to drop and undrop CVs and MVs (that are non-critical). In other words, to give them as much freedom as possible. Most plants fall into this category.

constraint limit without actually exceeding it. The analogy is a

The second school of thought is to lock down some param-

good one because if there is an abnormal situation (traffic jam

eters, for example some low and high limits. The operators

or slow moving traffic), then the driver can revert to manual

are limited to switching the APC on or off and changing only

control. Likewise, on a process plant, if there is a major distur-

essential limits, required for operation. The obvious advantage

bance or shutdown then the operators can revert to controlling

is that they cannot ‘clamp in’ a controller’s limits detrimen-

the plant manually.

tally, defeating its ability to control the unit. Also, if they

In this case, training the operators, showing them how

switch the APC off, it forces the engineers to address the

advanced control can benefit the smooth and efficient running

problem properly. The downside is that it may reduce good

of the process unit, and how it can make their life easier by

operators’ ability to be creative and think about more active

taking over a manual task, usually helps.

constraint monitoring. So whilst few sites operate this policy, it does prevent operators from clamping MVs.

Option of fixing limits Finally, there is an option of only allowing operators to turn

Conclusion

an APC scheme on or off and possibly changing a few key

Involving operators from the start of a project, training

constraint limits.

them well and then setting up a good maintenance system

There are two schools of thought on this. Depending on the site and the operators, one approach might work better than

is an essential part of retaining your investment in advanced control.

Chemeca 2019 – Call for papers open 29 September – 2 October 2019, Sydney, Australia The Chemeca 2019 Committee invites you to submit papers that explore the emerging opportunities and challenges for the chemical engineering profession and process industries throughout our region around the Engineering Megatrends and the Elements theme. Help shape the programme by contributing your work under technical research and innovation or industry practice topics. Abstract submission closes 15 March 2019. For more information including abstract submission and full list of abstract topics visit www.chemeca2019.org/call-for-papers19/ Chemeca 2019 is delighted to announce the initial plenary speakers; ■ ■ Jim McIlvenny, President - Dow Asia Pacific ■ ■ Kathryn Fagg, Chairman – Boral To register your interest and for more information visit www.chemeca2019.org

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 42 DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 42

tce.930/31.42.indd 2 boder DG.indd 42

06/12/2018 12:53 06/12/2018 13:30

feature process automation & control

Enhanced Cybersecurity Improves Plant Productivity? It is crucial that organisations do not allow cybersecurity and operational digitisation projects to happen in silos MARTY ISRAELS MARKETING DIRECTOR, HONEYWELL INDUSTRIAL CYBER SECURITY

I

T’S NO secret that cyberattacks on industrial systems

productivity by spotting issues such as atypical activities and

and critical infrastructure are increasing in both volume

system issues before they cause problems.

and sophistication. Today, cybersecurity measures are

an unavoidable day-to-day necessity. However, what many organisations don’t know is that these technologies can

The scale of the cybersecurity threat

deliver additional benefits over and above simply protect-

According to recent research from the World Economic Forum

ing the digital enterprise. Properly integrated as part of the

(WEF), cyberattacks are now the biggest concern for busi-

connected infrastructure of a plant, they can also help enhance

nesses in advanced economies. Further, the global exposure

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 43

honeywell DG.indd 43

06/12/2018 13:41

feature process automation & control

to risks from cybercrime is increasing as firms become more dependent on digital technologies. The explosive growth of the

Global expenditure on cybersecurity will rise from

Internet of Things (IoT) is expanding the surface area open to cyberattack, with the number of interconnected devices expected to jump from 8.4bn today to 20bn by 2020.

US$86.4bn

Risks can be mitigated if organisations take steps to protect themselves, but there is evidence that those in the process

in 2017 to a projected US$93bn in 2018

industries are failing to do so. For instance, a study from LNS Research1 found that just 37% of the oil and gas facilities surveyed are monitoring for suspicious behaviour, despite more than half having experienced security breaches in the previous year. The report indicates that “industrial companies woefully under-invest in industrial cybersecurity best practices across people, process, and technology, and survey results illustrate

targeted a wide variety of industrial sites, including refineries

shortcomings in all of these areas.”

and chemical plants around the world, and the threats them-

While modern, targeted cyberattacks are a major focus for most organisations, it’s important not to lose sight of long-standing threats faced by the sector, as well as the role

selves ranged in severity. About a sixth targeted industrial control systems or IoT devices. Worryingly,

among

the

threats

detected

were

high-

that end-user behaviour can play in exacerbating them. New

profile, well-known issues such as TRITON and Mirai, as well

research by Honeywell shows that removable USB media

as variants of Stuxnet, an attack type previously leveraged by

devices, such as flash drives, continue to pose a significant –

nation states to disrupt industrial operations. In compara-

and often intentional – cybersecurity threat to a wide array of

tive tests, up to 11% of the threats discovered were not reliably

industrial process control networks. While not a new problem,

detected by more traditional anti-malware technology. The

it does highlight how engrained user behaviour needs to be

data reminds us that it’s not just spreading malware, but mali-

constantly challenged and how hackers will exploit any means

cious misuse of USB devices to take over system controls that

possible to reach your control systems. The latest threats also go

comprises the threat.

beyond mere file infections, to taking over system commands remotely by exploiting the USB device.

Properly integrated as part of the connected infrastructure of a plant, cybersecurity measures can help enhance productivity by spotting issues such as atypical activities and system issues before they cause problems

Optimising industrial operations In part as a result of these significant threats, Gartner has forecast global expenditure on cybersecurity rising from US$86.4bn in 2017 to a projected US$93bn in 2018. At the same time many industrial manufacturers are currently in the midst of ongoing digital transformation journeys, creating plants capable of driving ever higher rates of productivity. Industrial Internet of Things (IIoT) technologies are generating large

The report’s data from 50 industrial locations showed that

quantities of new data for plants that can be analysed to deliver

nearly half had faced threats as a result of removable USB

valuable insights in order to optimise production. The cloud,

devices. Moreover, it revealed that 26% of the detected threats

and increasing connectivity across plants are transforming

were capable of significant disruption by causing operators

how engineers learn, share knowledge and go about their daily

to lose visibility or control of their operations. These threats

duties. To ensure ROI and optimal performance, it is crucial that organisations do not allow cybersecurity and operational digi-

The number of interconnected devices is expected to jump from 8.4bn today to 20bn by 2020

tisation projects to happen in silos. The implementation of enhanced cybersecurity technology and the upgrading of operational infrastructure, including next generation productivity tools, are both complex processes. Ensuring a smooth and seamless integration depends on collaboratively involving IT and cybersecurity experts from the outset. In addition, doing so can drive greater productivity benefits than piecemeal technologies alone. Properly implemented, this joint approach will not only build security capabilities into a business, but will also improve overall plant metrics. For example, thanks to new technologies

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 44

honeywell DG.indd 44

06/12/2018 13:41

feature process automation & control

such as industrial secure remote access solutions and inte-

implemented, which requires the understanding and support

grated industrial risk management software, safely accessing

of all employees, as well as ongoing collaboration. Centralising

data across multiple plants is far more achievable. Companies

command centres and operational control rooms while lever-

can now centralise their cybersecurity function, much in the

aging enterprise-wide security management solutions is one

same way as corporate structures facilitate other roles such as

way companies are looking to create efficiencies, while simul-

finance, marketing or legal.

taneously improving productivity and cybersecurity. Doing so

In practice, the infrastructure developed for cybersecu-

boosts knowledge sharing, increases staff retention, and allows

rity can be deployed as part of an integrated connected plant

more effective modernisation of plant operations through

process control network, feeding back data on equipment

connected plant strategies. Crucially, it also minimises plant

performance and monitoring for abnormalities, such as poten-

downtime.

tially malicious activity as well as maintenance-related issues. While this information helps safeguard operations against cyberattacks, it also provides valuable insights that can help

Knowledge is power to fuel plant improvements

optimise processes and equipment usage, identify bottle-

Plant and operations management are focussed on many dispa-

necks and generate data for a condition-based maintenance

rate tasks and objectives, which often forces security work

programme. Spotting issues and correcting deficiencies takes

to the wayside. Viewing security as an enabler for operations

place in real time, safely and securely. Protection and produc-

instead of an inhibitor, however, not only drives industrial

tivity are complementary goals – in a connected plant, digital

cybersecurity improvements, but also prompts smarter ways

data is no longer the sole preserve of a single operation.

of working.

Increasing cybersecurity with a connected plant approach Similarly, this combined methodology also makes cybersecurity more effective. By generating insights into potential vulnerabilities, the type and scale of potential damage is high-

Today the most advanced industrial leaders view and approach cybersecurity as a strategic initiative that will not only reduce risk, but will help justify equipment and plant modernisation and drive better business performance

lighted too. And with this information it will be possible to extrapolate the probable cost of an attack and how much long-

So where do you start? Industrial cybersecurity assessments

term harm would likely result. Investing in cybersecurity is not

provide objective, actionable information that can justify many

just about peace of mind, it should be seen as an opportunity to

needed upgrades to plant infrastructure. Such assessment

drive competitive advantage as well.

knowledge is powerful for articulating how cybersecurity work

Developing a properly designed and tested cybersecu-

impacts important initiatives, from quality improvements to

rity programme isn’t the end of the protection process – it is

digital transformation. And it can help meet daily needs, from

the start. In order for it to be effective it needs to be reliably

secure file transfers to properly-credentialed network users. By using assessment findings to engage cross-teams and corporate decision makers, engineering can document needs and

danger: removable usb media continue to pose a significant threat

gain the funding needed for important infrastructure updates that improve overall reliability, productivity, and efficiency. The results of assessments also might highlight gaps in available cybersecurity skills and lead to the decision to leverage expert partners. Managed security services can vastly improve staff productivity by outsourcing complex work that requires ample experience. It is important to understand that cybersecurity programmes and measures that align with your plant productivity needs may help you build a better business. Today the most advanced industrial leaders view and approach cybersecurity as a strategic initiative that will not only reduce risk, but will help justify equipment and plant modernisation and drive better business performance.

Reference 1. https://bit.ly/2BC1ls6

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 45

honeywell DG.indd 45

06/12/2018 13:41

feature icheme governance

YOUR

Congress

Putting your votes into action ANDREW THOMPSON DEPUTY PRESIDENT AND TRUSTEE LEAD FOR ICHEME CONGRESS

W

HEN I stood as a trustee in April, I was intrigued

We welcomed 50 nominations, and after a two-week campaign-

and excited by IChemE’s plans to reform governance

ing period and two weeks of voting, we announced the 32

and reinvigorate member engagement. The idea of

volunteers who would take up seats on the inaugural Congress.

a member advisory body coupled with the push for members

Members spanned the length and breadth of our member-

to nominate themselves as trustees, represented some of the

ship, with representation for student members, right through

biggest changes the Institution has made to governance in a

to Fellows. This is what makes Congress so special; it provides

generation.

every member, regardless of grade or location, with a pathway

Subsequently, at the Annual General Meeting in May more than 90% of members who turned out to vote on the new Royal

to make their voice heard, thereby ensuring that the direction of the Institution is informed by the views of the membership.

Charter and By-laws approved the establishment of a Congress.

Nominees took the elections seriously, and important issues

Furthermore, my fellow trustees and I were delighted to hear in

were hotly debated by candidates on our member-only forum,

June that Her Majesty the Queen had confirmed the approval of

Interface. This is exactly the kind of constructive debate that we

these amendments. This was a real milestone for the Institution.

need to continue with Congress. I have been an advocate of this

Finally, we could get to work on establishing a representative

development and welcomed my appointment as Congress trustee

body to channel the voice of our Institution’s membership.

lead. Congress is an integral part of the bigger picture that

Members far and wide were asked to stand. In fact, you may

IChemE is working towards. A member-advisory body, along

remember an article in the September issue of The Chemical

with the Board of Trustees responsible for delivering our char-

Engineer from my colleague Mark Sutton, urging the member-

itable objectives, will ensure that we are truly led by members,

ship to engage with Congress.

supporting members, and serving society.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 46

congress DG final.indd 46

06/12/2018 15:09

feature icheme governance

Being the voice, making a difference This has been an exciting, yet challenging, time. We need

Three members of Congress put their hats in the ring to be

to build on the momentum of change and enthusiasm of

Congress chair. The elections were held on the SharePoint

members. Like with any great idea, the disappointment of

platform based on a single transferrable vote. On 5 December

not living up to expectations can be very bitter. With the

we announced that Nigel Hirst was elected as chair of inaugural

best will in the world, it won’t be perfect. We must look to

Congress and Jane Cutler as vice chair as the runner up.

the horizon and how Congress can contribute to the Insti-

These members believe in the idea behind Congress as a

tution for years to come. Now it is time to get it off the

vehicle to deliver greater engagement across the Institution,

ground, work with newly-elected Congress members, feed

and are willing to put their name on it. However, every member

back and improve.

of this inaugural Congress will play a vital role in defining the

For the first time in the history of our Institution, all

identity of the advisory body.

members, including those who would not be able to vote at an

The Board of Trustees has already submitted agenda items

EGM or an AGM, were invited to vote on a matter that places

for consideration and, now that a chair and vice chair have been

members’ priorities and expertise at the heart of everything

elected, the agenda for the inaugural session of Congress can be

IChemE does.

set. Congress sessions will take place online, due to its interna-

More than 35,000 members worldwide were invited to vote in Congress elections. The overall turnout was 6.5% but it varied

tional nature and may last up to 30 days. An annual face-to-face meeting will help Congress members to work as a true team.

vastly between categories of membership and geographies. For

The current regulations, role description for Congress

example, 18.2% of Fellows cast their vote for their regional and

members, and terms of reference provide Congress a direction

functional representatives, with only 3% of student members

and a starting point for a new mechanism that no doubt will

(one of the membership categories that cannot vote at General

make a difference for our Institution. The election of a chair

Meetings) taking part. Why, you ask? You will be pleased to

and vice chair now means that Congress can manage its own

know that these are exactly the type of issues that Congress is

business and can change the rules that govern its operations

already touching upon even in its very early days.

and setup. This means that Congress is dynamic by design.

Following an induction in November, Congress is now picking

Thus, the Institution will continue to learn and evolve.

up at speed, and deliberations are already taking place on a

Congress is not a buffer between the membership and the

new SharePoint platform delivered by IChemE. This platform,

trustees but a sounding board, a new set of eyes and a trusted

exclusively for Congress members, allows them to contribute

advisor providing constructive proposals tested in a debate

to Congress business wherever they are based (time zones span

amongst a diverse group of members. Each functional and

from GMT-5 to GMT+13) and at their convenience – on the go,

regional Congress member gives you a simple and direct way to

at home or at work.

be part of the membership voice.

Figure 1: congress timeline Board of Trustees proposes draft regulations governing Congress and its operations

FEB

2018

Board of Trustees proposes draft changes to Royal Charter and By-laws

MAR 2018

Privy Council approves changes to Royal Charter and By-laws

MAY 2018

Members approve changes to Royal Charter and By-laws at the AGM

JUN 2018

Members submit their nominations to stand for Congress

JUL

2018

Board of Trustees approves regulations governing Congress and its operations

SEP

2018

Congress elects its chair and vice-chair and sets its first agenda

Members vote in a ballot for Congress seats

SEP

2018

Congress candidates campaign ahead of the vote

OCT

NOV

2018

2018

DEC 2018

Deputy president supported by trustees and chief executive hold induction for newly-elected Congress members

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 47

congress DG final.indd 47

06/12/2018 15:09

feature icheme governance

Functional college

Regional college

Figure 2: CONGRESS MEMBERS – FUNCTIONAL and REGIONAL COLLEGE

Accountable to you

Functional College this is higher, at 35%. Congress has six seats

The way we have conducted the nominations process has been

allocated to represent members who are either students or in the

done to ensure that the inaugural Congress represents our

early stages of their career to create a good mix of more expe-

diverse membership as closely as possible. Despite not receiv-

rienced members and those who represent the future of our

ing any nominations for some seats, we have members from

profession.

Australia, Singapore, Malaysia, Ireland, Spain and various

As the Congress is beginning to plan for its opening session,

regions across the UK being represented through the Regional

it really couldn’t be a better time for you to start thinking about

College. I was also delighted to see that for every category of the

the types of issues you think Congress should be debating. They

Functional College we received more nominations than seats.

are your representatives and they can only truly be the voice of

What’s more, 21% of Congress members are female, which is consistent with our overall membership breakdown. In the

the membership if they are informed on issues by you. There is no limit to the topics that can be raised with a

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 48

congress DG final.indd 48

06/12/2018 15:10

feature icheme governance

Figure 3: CONGRESS STEERING GROUP – FEEDBACK LOOP

Congress steering group Chief executive

Trustee lead

Congress vice-chair

Congress chair

Set agenda and manage outcomes

Channel feedback Staff members

Board members

Advise/ comment

Congress

Update/ consult

Board

Decisions influenced by Congress

Congress members

IChemE strategy and operations

Member input

Impact on society

IChemE members Reflection on IChemE’s benefit to society Benefit to society

Congress member, but I urge all members to think about our

Your feedback is important. Congress members are expected to

chemical engineering profession outside of the IChemE bubble.

channel any member feedback they receive to the chair and vice

Governance and operations are undoubtedly important issues but

chair, who will use it to set the agenda for Congress and manage

looking outward to wider societal impact is equally important.

outcomes to ultimately advise the Board of Trustees. Trustee

Think about the future and how chemical engineers are going to be affected. Perhaps there is something in your regional

decisions drive the strategic direction of your Institution which has both an impact on society and our members. (see Figure 3).

locality that you feel IChemE needs to address? Or is there a

I trust this article has encouraged you to become more

development in your area of discipline that Congress should

engaged in IChemE activities through Congress. Please join me

know about? This is where you can really help IChemE to harness

in supporting Congress members and helping them to make it

its responsibilities as a learned society and as a trusted advisor

a success.

on issues affecting chemical engineering.

Congress was created in order to give members a voice in the decision-making at IChemE. However, establishing it is just the beginning. It can only be a success if the rest of the membership engages with Congress members and their activities

Reach out to your Congress members Remember, this is your Congress and the representatives are accountable on issues that affect you. Getting in touch is easy:

✓ Visit

the

new-look

website

at

www.icheme.org

and visit “About” > “People”. This is where you can Finding out about your Congress members couldn’t be easier now

read about each Congress member and get in touch

that we have a new-look website. Launched on 29 November, the

with them about a topic or issue that you think the

new website makes it much simpler for you to find information,

Institution should be addressing.

access resources, and catch up on the latest news and events. We have a dedicated Congress section on the new site so if you haven’t already, head to www.icheme.org to check it out. Congress was created in order to give members a voice in the decision-making at IChemE. However, establishing it is just the beginning. It can only be a success if the rest of the membership

✓ Log in to Interface, our member-only online forum (accessible through MyIChemE) and visit our dedicated Congress section to post your own questions or comments.

✓ Invite them to your meetings whether it is a member group networking session or a talk at your university.

engages with Congress members and their activities.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 49

congress DG final.indd 49

06/12/2018 15:10

feature year of engineering

Adam Duckett speaks to engineers, schoolchildren and teachers who took part in the UK government’s outreach initiative

2

018 was the UK government’s Year of Engineering – a

Luca, aged 12 from Matthew Arnold school said: “They were

campaign aimed at raising public awareness of the profes-

explaining what the drones were used for and how different

sion, in part by building on the outreach activities organised

robots help BP and the oil industry. And then they were flying

by industry employers.

the drones around showing off the camera and what it’s made

Fresh from hosting events showcasing what engineers do, we

out of…it was really interesting.”

caught up with member volunteers from a selection of IChemE

Classmate Toby, aged 13, said: “I quite liked the umbilicals and

Corporate Partners and accredited company training scheme

all the cables they had to lay. It was quite interesting learning

(ACTS) providers, and the schoolchildren they were seeking to

about all the ecosystems that develop around it due to it heating

inspire.

up the water.”

First up was an event hosted by BP at its campus in Sunbury on

BP process safety engineer Ben Jones said he was impressed by

Thames, for children aged 13–14 visiting from two local schools.

some of the children’s reactions to his demonstration on fire and

For the first half of the day, the children toured six zones in

explosions, in which he asked how a building could be engineered

small groups learning from engineers about subsea engineering,

to protect people inside.

computer aided engineering, shipping, innovation in engineering,

“Some of the answers we got were brilliant. I remember one

geology and robotics. This latter zone included a hugely popular

boy saying: ‘could you try to vent the explosion out of one of the

drone demonstration by one of BP’s suppliers.

walls? Have one wall weaker so that it would fail first’ – which is a very clever idea.”

More than a petrol station Asked what he would be telling his parents about the event when he got home that night, Luca said: “Beforehand, me and my parents thought ‘isn’t BP just a petrol station?’ But now we know all the stages [of industry in which they work] and how far back it goes with the extraction of the raw materials and then the refining. “I’ll go home and say ‘well actually this is how that works and did you know that BP is more than a petrol station – it’s a full blown company that does pretty much most things!’.” Nick Elliott, a teacher at Matthew Arnold School, said the event was valuable for schoolchildren. “It allows them to see a broader range of experiences; the

budding engineers: BP volunteers with students from Matthew Arnold School

different type of role in the industry that you can come and do. The site will be something that many won’t have experienced before, so it gives them a chance to see what a working environment

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 50

YoE DG.indd 50

06/12/2018 15:29

feature year of engineering

holding water: pupils set fast-paced design challenge

Engine Ears Atkins produced this wonderfully funny animation to explain that engineering is exciting, creative and a brilliant future for people who love to dream up ideas: https://youtu.be/HoHGChziqeE

Imperial Enginuity Engineers from Imperial College London explain what engineering means to them and how it makes the world a better place: https://youtu.be/tDqXl7BiJCU

Training with LEGO Find out how LEGO education and IET have been training actually looks like, which is completely different to a school. “I would encourage any other medium-to-large companies to give this a go and see what they can do to get children into their organisations.” Later that day, the students were set an engineering challenge that involved working in teams, overseen by a BP engineer, to design a platform jacket. The students were given a choice of building materials to buy including scissors, straws, and Sellotape,

STEM ambassadors to deliver cool workshops in schools: https://youtu.be/HmacZnqQC5w

Glitter bomb Engineers create an underwater glitter bomb to show how plastics spread in the sea, and explain how engineers are helping to boost sustainability of materials: https://youtu.be/8sq5MOf4yE0

and a BP design requirement including the structure’s minimum

Open Doors

height. They had 30 minutes of engineering and procurement time

KBR opened its UK headquarters in Leatherhead to more

to brainstorm and design their platform, and then 45 minutes to

than 500 visitors, including children, parents and university

build it. The winner was the platform that held the most water

students. Look inside as they discover the careers available to

bottles at the lowest cost.

engineers, and get hands on with interactive displays and 3D models: https://vimeo.com/288205763

Women in engineering Valero ran a similar event aimed exclusively at local schoolgirls, at its Pembroke, Wales, refinery. Part of the Year of Engineering’s mission is to help address lack of diversity in the profession, which is estimated to be 91% male. The event included hands-on activities led by Valero engineers, a robot programming challenge, and a guided bus tour of the refinery. Asked what had inspired her most, Rhiannon, 13, from Ysgol Penrhyn Dewi, said: “The robot at the start. We had to programme a robot that was meant to be a boat to go around the river.” Rhiannon wants to be a vet and said the event inspired her to try harder at science. School governor Lindsey Richard said: “It’s inspirational for this age group to see a place like this to inspire them about what else is out there. When you live in a small community it’s quite difficult to envisage what other opportunities are available.” She revealed that a female director of Valero had changed her own perceptions on the opportunities available to women in

come on in: KBR shows us what engineers do

engineering.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 51

YoE DG.indd 51

06/12/2018 15:29

feature year of engineering

sciences – if we just get a few that are interested in developing their careers in that direction – it’s all positive.” “Anything that encourages the younger generation to develop into engineers…is important for the country and for developing industry.” IChemE Member Charlotte Lewis who volunteered to help with the hands-on demonstrations said: “I got involved in a couple of days like this when I was a student in secondary school and it’s what inspired me to go on and do chemical engineering. I think it’s very worthwhile. You are there to inspire the future generation.” “I think it’s quite important … to try and sow those seeds quite

robot challenge: hands-on programming

early on.” Also taking part was Karen Muehlbauer, director of health and environmental safety at Valero’s Pemboke refinery. She says it is crucial to make girls aware that STEM isn’t boring – that it’s

“She spoke about her experience…a lot of us thought is she an

exciting and provides a vast array of opportunities.

engineer? Is that possible? What does she do? She did explain

“This is a passion in my life. I really want girls to have oppor-

that initially she thought she was going to go into makeup, and

tunities in STEM. I love it and want to share that love. I have a

design eye shadows…and all of a sudden she’s working in a

little daughter and she knows mommy does science.”

plant that’s [refining] crude oil and sending it off as petrol and diesel. It’s just about educating people.” Neil Harvey, an IChemE Fellow at consultancy OSL, helped

“I think for some reason we have this unconscious bias and so I don’t think girls get the opportunities…I think it’s very important to expose them to STEM earlier on.”

run a tour and engineering challenge at the company’s office in

IChemE Fellow Badrul Huda, BP audit manager of upstream

Hull. The 10–11 year olds were brought in by a local charity called

operations, said he thinks it’s important to engage because

Hull and East Yorkshire Children’s University which introduces

children are having their heads turned by careers at worldwide

children from disadvantaged areas and schools to STEM activities.

tech firms like Apple and Microsoft.

“We did an activity with them where they had to find a way of

“The big companies now are not necessarily oil and gas compa-

getting water from one bottle to another. The full bottle was on

nies…Do people necessarily think engineering, law and medicine

the floor and the empty bottle was on the table. So, it was about

are the best careers to go into or do they think of programming,

pressure, and pressurising the bottom vessel and pumping it up

IT systems and design as more attractive?”

into the top vessel.

Huda added that it is important for young engineers to engage

“Then we had a race – the first one to empty the bottle at the bottom into the top won.”

with schoolchildren who may find it easier to relate to them. “I would encourage more engineers and scientists who have just recently joined industry to go and talk to students and tell

Put your hands up On why he had volunteered, Harvey said: Trying to get kids interested in STEM activities and engineering is really fulfilling. “If they show an interest in becoming engineers or the

them why they are doing it and what is most interesting about it – and showcase the kind of things they are doing. It’s really important.” There is value in the personal reflection that comes before the event too, said Jones. “As I was preparing for it, I found it made me think about my job in an interesting way: what I was doing, why I was doing it, which aspects of the job I found most fun, and then how can I explain that in a very simple way? I quite enjoyed that moment of reflection – it was quite good to take myself out of my day job and prepare for this.” All of the engineers we asked agreed that companies and individuals should seek greater engagement. Muehlbauer said: “It pays back because you’ll hopefully get them four or five years from now. They’ll eventually come and work – maybe not for us – but somewhere. More diversity is always more success, more ideas in the room.” As 2018 draws to a close, the profession must find a way to

valero: targetting diversity issues with girls-only event

maintain the momentum built up by the Year of Engineering. As we go to press, discussions are underway about how to carry this impetus into 2019.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 52

YoE DG.indd 52

06/12/2018 15:29

feature year of engineering

WESTMINSTER ABBEY ENGINEERING was the focus of celebration at a first-of-a-

“Like thousands of women before me, I will depend on

kind national service held at London’s Westminster Abbey.

the doctors, scientists and engineers that have relent-

On 22 November, guests from across the engineering

lessly worked to engineer babies, and I am thankful for the

community, including trustees of IChemE, gathered with

innovative medicine, engineering equipment and scien-

politicians and schoolchildren to mark the government’s

tific breakthrough that has allowed us to literally create life,”

Year of Engineering. The multi-faith service celebrated those

Agrawal said.

inspiring the next generation of engineers and engineering greats, including Thomas Telford and Robert Stephenson who are buried at the Abbey. Secretary of state for transport Chris Grayling said: “In a year which has seen government and industry join forces to raise the bar for inspiring the next generation of engineers, what could be more fitting than to come together to celebrate the contribution that engineers have made and will

“We hope future generations will be inspired by the opportunities engineering offers to shape their world, to discover new ways to improve lives in the future and to help meet the needs of the twenty-first century and beyond”

continue to make to all of our lives? “I hope today’s service serves as an important reminder

Dame Ann Dowling, president of the Royal Academy of

not just of our proud engineering history but of the role

Engineering, said: “Engineering expertise will be critical to

young people will play in writing its next chapter.”

tackling the global challenges we face in the years to come.

The service led by John Hall, dean of Westminster, included

Engineers will play a central role in addressing the effects

personal testimonies from engineers on how the discipline

of climate change and rising sea levels, and in ensuring that

has changed their lives and enabled them to help inspire

our growing population will have access to food, water, clean

others through their work.

energy and affordable healthcare. We hope future genera-

Roma Agrawal, associate director of AECOM and famed for

tions will be inspired by the opportunities engineering offers

her work on the Shard skyscraper, offered a heartfelt account

to shape their world, to discover new ways to improve lives

about how engineering is her present and her future, refer-

in the future and to help meet the needs of the twenty-first

ring to the fact that she will undergo IVF to get pregnant.

century and beyond.”

e Akinola (pictured) of Laing O’Rourke, read the ny Yewand Boxout: YoE poem At the Westminster Abbey ceremo an: Narayan At the Westminster Abbey ceremony (see boxout) Yewande poem What is an Engineer? by Varun Akinola, of Laing What is an engineer? Well, look around: O’Rourke, read the Our monuments are everywhere – we make poem What is an and speculate, design, create, and build, Engineer? by Varun then bridge the continents or search the stars, Narayanan: bring information into every hand, What is an shape air and fire, sea and land – each one engineer? Well, an element with which we innovate, look around: imagining how lives might be improved. Our monuments are now, – we make everywhere To generate the new, the future all kinds, design, of unds backgro from and speculate, ingenious,

time, and build, inventing at all ages, for all create, minds, t h e n with individual spirit and joined to tackle any challenge, far or nearis what it means to be an engineer.

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 53

YoE DG.indd 53

06/12/2018 15:29

feature ICHEME AWARDS

win-win: this year’s global awards recipients show off their trophies

Waste-to-BioSNG innovation wins big at IChemE Awards Event demonstrates the contribution chemical engineers are making wor wi e or the enefit o societ AMANDA JASI REVIEWS THE WINNERS OF ICHEME’S ANNUAL AWARDS PROGRAMME

A

NEW technology that converts solid household waste

Massimiliano Materazzi, senior research fellow in the chemical

into sustainable bio-energy has won the top prize at

engineering department at UCL, said: “I am extremely

the IChemE Global Awards 2018, held in Manchester,

delighted that our work on waste-to-BioSNG was recognised at the IChemE Global Awards with three first prizes. These

UK on 1 November. The winner of the Award for Outstanding Achievement

awards are the icing on the cake for a project which started

in Chemical and Process Engineering was a joint project by

more than six years ago, and which has been a fantastic engi-

Advanced Plasma Power, University College London (UCL),

neering journey. The consortium team has worked very hard

Cadent Gas, and Progressive Energy – all based in the UK. The

to develop and test a new approach to one of the key issues

project, Converting Waste to BioSNG, also won the Sustainability

in the environmental and energy sector: dramatically reducing

Award and the Energy Award.

the volume of waste to landfill whilst at the same time decar-

The technology uses a unique gasification and catalytic

bonising both heat and heavy goods transport – sectors in

process to turn household waste into bio synthetic natural gas

which it has been extremely difficult to reduce greenhouse

(BioSNG), a low-carbon, renewable gas. The team has launched

gas emissions to date. I believe that BioSNG will be one of a

the world’s first commercial demonstration plant to produce

number of innovative game-changing technologies to achieve

the gas, which is used to heat homes across the UK and power

these targets.

heavy-duty vehicles and buses.

“Winning these awards recognises both our innovative

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 54

awards DG.indd 54

05/12/2018 13:58

feature ICHEME AWARDS

solution and collaborative model between industry and univer-

failure. His insights have driven the design of the latest lithi-

sity. I really look forward to continuing my work with the team

um-ion batteries, used in NASA’s manned space applications.

in helping commercialise the technology.”

The Water Award went to University of Malaya and Berqat Mechanic Engineering, for their solar-power enabled

processes and people

self-cleaning filtration system. The novel technology cleans water from rivers, underground and springs without using

Woodside Energy was crowned the winner of the Process Safety

chemicals. The process is currently providing cheap, clean

Award for its use of IBM’s Watson computing system to search

water to remote villages in Malaysia.

through more than 500,000 historical data records within hours instead of days, boosting Woodside’s accuracy of risk assess-

innovations

ment and hazard identification. The Environment Agency (EA) scooped up the Diversity &

Green technology companies Enerkem, Canada, and Green

Inclusion Award. The EA has created an inclusive workplace

Lizard Technologies, UK, won the Biotechnology Award and

that values and embraces difference. This allows employees to

Business Start-Up Award respectively. Stora Enso, Finland,

bring their whole self to work, progress their career, and feel

was presented with the Innovative Product Award for creating

their uniqueness is valued.

a new bio-based, sustainable material to replace fossil-fuels.

“We’re delighted that the Environment Agency has been

The material is used in coatings and adhesives.

recognised by IChemE for its commitment to diversity and

Sellafield Ltd triumphed in two Award categories. Part-

inclusion,” said Marie Fallon, director of regulated industry at

nered with Progressive Alliance and AXIOM, it won the Team

the EA. “Our chemical engineers use their valuable skills for

Award for developing a new facility that allows the safe, long-

the benefit of the people and the environment each day, and

term storage of plutonium. Rojiar Ferschy won the Young

we know that an inclusive staff culture is essential for their

Industrialist Award. Ferschy is currently developing solutions

wellbeing and productivity, which is what underpins this great

to support Sellafield’s plant operations responding to global

work.”

nuclear challenges. She is a passionate advocate of chemical

GSK, PM Group, Suncombe and ITT won the Pharma Award

engineering, and volunteers her free time to mentoring

for designing a fully-automated sterile filtration unit. It has

aspiring engineers and teaching English to Kurdish refugees

eliminated the risk of contamination, which can happen before

at camps in Iran and Turkey.

or after sterilisation within a manual process.

Rolls-Royce walked away with the Industry Project Award

James Finn, a former pharmaceutical process engineer at PM

for successfully constructing a new, complex manufacturing

Group who was involved in the project, said: “We felt that it was

facility. The Food & Drink Award went to Monash Univer-

an amazing accolade to just be chosen as one of the six final-

sity in Australia for its spray-drying technology for the dairy

ists in the Pharma category, but to win it as well was incredible.

industry. The first of its kind, it has improved energy effi-

Given the calibre of the other nominations within the Pharma

ciency and reduced waste for its commercial partners, who

category it gave us all great satisfaction that a judging panel

produce around 70% of Australia’s milk.

of our peers valued and recognised what we have done; imple-

Johnson Matthey, US, won the Oil & Gas Award for its project

menting some novel technology and processing operations on

tr ct re

tea

e or in

ata st. Meanwhile,

site. It was a great project to work on, with a team fully aligned

the Research Project Award went to Imperial College London,

to resolving a significant pharmaceutical processing issue, and

UK for its

resolving it with good, solid engineering. We are very proud of

crowned the winner of the Training and Development Award

what we have achieved and feel that the award acknowledges

for its nucleargraduates programme, which is successfully and

the success that we have achieved as a collaborative team, with

cost-effectively attracting and training new, young engineer-

the co-operation, focus, and expertise of the personnel involved

ing talent the nuclear sector.

key to that success.

e t

eneration

ri

o ar

ste s. Energus was

Ken Rivers, president of IChemE, said: “The IChemE

“It has been a pleasure to work on this project and I hope

Global Awards are a clear demonstration of the contribution

that this collaborative team-focussed approach will become

chemical engineers are making worldwide for the benefit of

the norm for future projects throughout the sector. Whilst

society. Every finalist is living proof that chemical engineer-

acknowledging the excellent core team, it would be good to take

ing matters. Thank you to our judging panel, which every

the opportunity to thank all of the dedicated personnel involved

year has the significant task of reviewing each entry - and

in the project from GSK, Suncombe, ITT and PM group, who all

they do so on a completely voluntary basis. For our winners,

worked very hard to ensure the success of this endeavour.”

this peer-review is what makes an IChemE Award so special.

The Young Researcher Award was won by Donal Finegan of

As president of the Institution, I’m so proud to have seen

the Department of Energy’s National Renewable Energy Labo-

first-hand the fantastic work that our professional chemical

ratory, US. Finegan has become renowned in the international

engineering community are doing. Congratulations to all our

battery community for his rigorous investigations into battery

deserving winners.”

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 55

awards DG.indd 55

05/12/2018 13:58

news icheme

governance

Thompson elects not to become president in 2019 ICHEME’S

trustees

much to do, the direction of travel is excellent and the speed of

the

change appropriate to an institution of our standing. The Insti-

decision of the deputy

tution is in good hands, and in better shape than was apparent to

president,

Andrew

the wider membership at the time of my appointment.”

Thompson,

to

have

accepted

not

The Board of Trustees said it respects the decision and is

president

greatly encouraged by Thompson’s commitment to work dili-

Institution’s

gently and passionately for the Institution for the duration of his

become at

the

AGM in May. In his letter to IChemE pres-

time as deputy president. “For the remainder of his term Dr Thompson will provide

Rivers,

a vital bridge between the Board of Trustees and the newly-

Thompson stated that

elected Congress, support the Strategy 2022 rollout by the Board

owing to a combina-

of Trustees, and continue in his role as the chair of the newly-

tion of professional

formed Communications Panel Committee,” it said in a

and

statement.

ident

Ken

domestic

cir-

cumstances, he had

Rivers said: “Andrew is clearly a great believer in IChemE as

concluded that it is

the Institution supporter for all chemical engineers around the

no longer in his own

world. He really is a members’ champion. This is an authentic

interest or that of the Institution for him to proceed to the role.

and brave decision and many would have not have had Andrew’s

Thompson wrote: “Since the AGM, I have come to under-

self-awareness to put the Institution first. I admire this greatly.

stand that many of the ideas, ambitions and concepts that we

I have no doubt he will be a very strong institutional supporter

had, as members on the ‘outside’ (remote from the trustees)

and reformer for many years to come. I sincerely hope so.”

requested, are already in motion and meet with many of our expectations. This is hugely encouraging and while there is still

The Board of Trustees will confirm, following their meeting on 17 January 2019, the process of electing a new president.

awards

Jacquie Manning

Judy Raper named Australia’s top female engineer JUDY Raper (pictured left),

universities of Newcastle, Sydney, UNSW and Missouri University of

a chemical engineer with

Science and Technology in the US. She is a former director of chem-

expertise in air and water

ical, bioengineering, environmental and transport systems at the US

pollution control, has been

National Science Foundation, and worked at the UK’s Atomic Energy

awarded the Ada Lovelace

Research Establishment.

Medal

for

Outstanding

The

national

“I am thrilled to be recognised by my peers with this award, especially as it is named for Ada Lovelace who was a true innovator

Woman Engineer. award

and a truly inspirational woman,” Raper said.

is given annually by the

“In terms of diversity, engineering has come a long way since I

University of New South

began my career in the 1980s, but we still have a long way to go.

Wales faculty of engi-

We have gone from 6% of engineers being women then, to around

neering in recognition of

18 or 20% now, so there is a lot of room for improvement still, and

the contribution women have made to the profession and to wider

we in the university sector have a big role to play in keeping up the

Australian society.

momentum for change.

Raper, who is deputy vice-chancellor (research and innovation)

“For engineering, achieving greater diversity in all its forms

at the University of Wollongong, collected the medal at a ceremony

is important not just because it is the right thing to do, but also

at the Botanic Gardens Restaurant in Sydney in November. Her

because it will lead to greater innovation and to better solutions to

career has included education and management roles at Australia’s

the complex problems that the world faces.”

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 56

ichemenews930 DG.indd 56

06/12/2018 16:01

news icheme

student members

UCC wins All Ireland Chemical Engineer Sports Day (UCD), University of Limerick (UL) and Cork Institute of Technology (CIT) gathered on 2 November to play basketball, dodgeball, football, handball, tennis, and run the relay. The event culminated with a thrilling final, as UCC beat UCD in basketball to clinch first place. UL came third and CIT fourth. The event was organised by UC fourth-year students Killian Doyle and Eimear Duggan. Doyle thanked his co-host and all the students that attended for helping make it such a successful event. “An event like this allowed them to make friendships, which we know will stand to them as they advance in their future careers. A big thanks must go to the staff and students of the process and chemical engineering department in UCC, in particular AnneUNIVERSITY College Cork (UCC) took sporting gold at the 4th

Marie McSweeney, Denis Ring and Ed Byrne, who all gave so much

All Ireland Chemical Engineering Sports Day, maintaining its

help to ensure the event was a success for everyone involved. Also,

unbeaten winning streak since the annual event was launched

thanks must go to the Mardyke Arena for allowing us to use their

in 2015.

fantastic facilities. And finally we would like to thank MSD, AbbVie

More than 250 students from UCC, University College Dublin

and IChemE for providing sponsorship for the event.”

governance

publications

Upcoming trustee elections

Protecting future energy infrastructure from natural hazards

JUST

over

IChemE

six

passed

months a

suite

ago of

ICHEME has supported the Energy Technologies Institute (ETI) in

changes to its Royal Charter

publishing research identifying how natural hazards can be char-

and By-laws. Since then, a lot

acterised to help improve energy system infrastructure design

of focus has been on our new

and inform investment decisions.

member representative body,

The project,  Enabling Resilient UK Energy Infrastructure:

Congress. But we must not for-

Natural Hazard Characterisation Technical Volumes and Case

get that the Board of Trustees

Studies, was funded by ETI and delivered by EDF Energy, the Met

was also reformed to improve accountability to you, the

Office, and Mott Macdonald. It has 12 technical volumes that

members.

summarise the methodology of natural hazard characterisation

The board has committed to ensuring that your Institution is truly led by members, supporting members and serving society.

and five case studies of UK sites to showcase the demonstration of these methodologies.

The trustees, including those elected earlier this year have been

IChemE Fellows Helen Fennell, director at Inherent Safety

enthusiastically working on new initiatives such as establish-

Consulting, and John Munnings-Tomes, chief risk engineer at

ing Congress, improving member engagement and ensuring that

Navigators Technical Risk, contributed to reviewing and finalis-

the correct systems are in place to deliver the Institution’s learned

ing the study. The publication was launched on 12 November at

society obligations. It has been great to see new thinking and new

an event hosted by IMechE and IChemE.

ways to engage members in the affairs of your Institution.

Mike Middleton, strategy manager at ETI who ran the pro-

The elections for trustees and later Congress have led to a lot

ject, said the knowledge “can apply to new assets during design,

of interesting debates and exchanges. This constructive action puts

or investment in existing assets through upgrades or life exten-

member expertise and societal benefit at the heart of everything

sion. Although developed in association with the UK’s energy

IChemE does. There is no doubt that the next trustee election will

system, the knowledge potentially has relevance to broader

build on the momentum of change. Keep an eye out for further

infrastructure, including transport and the built environment.”

opportunities to take part in 2019 and ask yourself, how will you

Download the documents at: https://bit.ly/2E1HtQi

play your part?

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 57

ichemenews930 DG.indd 57

06/12/2018 16:01

2019 Training Courses IChemE is a market-leader in training for chemical and process engineers. All our course content is peer reviewed and delivered by topic experts. Our courses are also available for in-house delivery where content can be customised to meet your specific learning needs. Courses include: Process Safety ■■

■■

■■

■■

MB0055_18

■■

Process Operations

Fundamentals of Process Safety www.icheme.org/fundamentals

■■

HAZOP Leadership and Management www.icheme.org/hazop-leadership

■■

HAZOP Study for Team Leaders and Team Members www.icheme.org/hazop-team

■■

Human Factors in Health and Safety www.icheme.org/human-factors Layer of Protection Analysis www.icheme.org/lopa

Chemical Engineering for Other Engineers www.icheme.org/chemical-engineering Chemical Engineering for Scientists www.icheme.org/scientists Practical Distillation Technology www.icheme.org/distillation

Contract and Project Management ■■

IChemE Forms of Contract www.icheme.org/forms-of-contract

Download our 2019 Training Catalogue at www.icheme.org/training-catalogue Don’t see what you’re looking for? Contact [email protected]

MB0099_18 tce FP AD Courses.indd 1 tce.930/31.58.indd 2

06/12/2018 11:05 06/12/2018 13:10

The Chemical Engineer letters SEND YOUR FEEDBACK TO [email protected], @TCEMAGAZINE, FACEBOOK.COM/TCEMAGAZINE

3D printing promise new separations manufacturing,

in

with my method, which I think is probably

ogy

addition

Jean Luc Atteleyn

Additive

feature reactor technol room for improvement?: air liquide’s smr plant

to

easier, and more effective. Having cut my apples in half, I load them into plastic bags, and put them in

enabling better chemical reactors for process intensification (p19, issue 928), may enable

the freezer. When the next lot of apples is

another revolution in separations.

available I repeat the process but first take the frozen apples out of the freezer. These I

There are many separations that could be done by distillation except the temperatures are above normal materials limits. additive

manufacturing

out

of reactors can help chemical engineers with process inten sification

1

A

RAPHAËL FAURE 1; MATTHIE U FLIN 2; PASCAL DEL R&D PROJECT MANAGE 2 GALLO 3 AND MARC WAGNER 4 R; R&D ENGINEE R; 3R&D MANAGE R; AND 4R&D MANAGE R, AIR LIQUIDE

DDITIVE manufact uring technolog y – or 3D printing, as it’s more commonly referred to – has, since emerged in the it early 80s, advanced pace. Originall at a tremendo y associated with us industrial parts turing and tooling, manufacthe techniques have lately been areas as diverse applied in as manufacturing, medicines, food, and are even available clothing to the home enthusias equipment and t, with the right a knowledge of CAD. At Air Liquide, we’ve been using the technique of metal 3D printing (in the form of reactors) to work on finding ways to

of

refractory metals including molybdenum. This enables manufacture of distillation columns with complex internals that could

evening they will be thawed out so I load a

How 3D printing

The jet engine community has been developing

leave overnight in a large container. The next

Add It Up!

R&D

improve traditiona l chemical manufact uring processes started by looking . We for more efficient ways to produce from methane hydrogen in the well-kno wn steam methane (SMR) process. reforming

Why improve

SMR? Hydrogen is one of the most abundant elements on the an essential molecule Earth, for chemistr y, and mostly used fuel desulfurisation for fossil and for productio n of fertilisers . It also

OCTOBER 2018 | The Chemica l Engineer airliquide DG.indd

domestic press (the sort you can obtain from a

| page 19

home brew shop) and screw down. All the cells of the fruit, having been frozen, then thawed, are broken down and the screw press takes little or no effort. The juice pours out of the

19

19/09/2018 14:18

operate above 1,200oC. In the nuclear field

press free from any pulp. The volume of fruit reduces to 20% and the volume of juice is 80%.

this may enable economic purification of liquid salts for salt-cooled reactors. There are likely to be many other

It requires no further straining, and certainly no additives.

high-temperature inorganic separations where distillation is

Neither have the apple trees been sprayed with herbicides, pesti-

now a real option.

cides, or bird repellent. The cutting in half of each apple helps

Charles Forsberg

the freezing and squashing process but also allows a visual check

US

Thaw point

for worms etc. I produce about 50 L of juice each season. I had considered

I read Amanda Jasi’s article “Chemical Engineering in the Kitchen”

fermenting the juice but it is so pleasant as fruit juice, that is

describing Nevin Stewart’s method for extracting juice from

how I leave it.

apples.

Michael Menzies

I too have access to many apples and so, several years ago,

UK

developed my own method of apple juice extraction. Looking at the photographs and reading the article I have decided to stay

EDITORIAL Editor: Adam Duckett, [email protected], @adam_tce, +44 (0)1788 534469 Managing editor: Delyth Griffiths, [email protected], +44 (0)1788 534424 Staff reporter: Amanda P Doyle, [email protected], @amanda_tce +44 (0)1788 534404 Staff reporter: Amanda Jasi, [email protected], @tce_ajasi +44 (0)1788 534426 www.thechemicalengineer.com @tcemagazine www.facebook.com/tcemagazine

PRODUCTION Graphic designer: Alex Revell, [email protected], +44 (0)1788 534421 Advertising production: Lyzanne Cox, [email protected], +44 (0)1788 534486

ADVERTISING SALES – MEDIA SHED Display, classified & directory: Ian Hartley, [email protected], +44 (0)20 3137 8581 Recruitment: Freddie Richardson, [email protected], (0)20 3137 8583

MAGAZINE SUBSCRIPTIONS Visit www.thechemicalengineer.com/register to view options to subscribe

PUBLISHER Claudia Flavell-While, Institution of Chemical Engineers, Davis Building, Rugby, CV21 3HQ, UK +44 (0)1788 534422

The editor reserves the right to edit all letters.

Statements and opinions expressed in The Chemical Engineer are the responsibility of the editor. Unless described as such, they do not represent the views or policies of the Institution of Chemical Engineers. The Editor and the Institution do not accept liability for any incorrect information written by the authors of articles. All rights reserved. Multiple copying of the contents of the publication without permission is always illegal. USA authorisation to photocopy items for internal or personal use or the internal or personal use of specific clients is granted by The Institution of Chemical Engineers for libraries and other users registered with the Copyright Clearance Center (CCC) Transactional Reporting Service provided that the base fee of US$7.00 per article is paid directly to CCC, 21 Congress Street, Salem, MA 01970, 0302 0797/98 The Chemical Engineer (ISSN 0302-0797) is published monthly (with a combined December/January issue) by the Institution of Chemical Engineers, Davis Building, Railway Terrace, Rugby, Warwickshire, CV21 3HQ, UK. Periodicals postage paid at Rahway, NJ. US agent: Mercury Airfreight International Ltd, 365 Blair Road, Avenel, New Jersey, 07001. Postmaster: Address changes to Mercury Airfreight International Ltd, 365 Blair Road, Avenel, New Jersey, 07001. Printed in the UK by Lock Stock & Printed © The Institution of Chemical Engineers 2018 IChemE is a registered charity in England & Wales (214379), and a charity registered in Scotland (SC 039661) ISSN 0302-0797

ICHEME MEMBERSHIP ENQUIRIES Membership department: [email protected]; www.icheme.org, +44 (0)1788 578214 Scottish Members Group

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 59

letters930 DG.indd 59

06/12/2018 13:42

The Chemical Engineer events FOR A FULL LIST VISIT WWW.ICHEME.ORG/EVENTS UNITED KINGDOM Hydrogen, Methane, Electrons – Low Carbon Heating of Homes London, 8 january 2019 A technical talk from Andy Cornell of Go Green Fuels discussing the chemistry of decarbonising heat, together with the technical and economic challenges of moving away from fossil gas. www.icheme.org/low-carbon-heating

North Lancashire Members Group – The Faraday Challenge Preston, 2 january 2019 It is hoped that the Faraday Challenge (£246m in research funding on a four-year energy storage strategy focussing on battery innovation) will break down barriers to new battery technologies and introduce new business models. The presentation aims to look at research in this sector in more detail. www.icheme.org/nlmg-faraday-challenge

Imperial College Carbon Capture Pilot Plant Tour London, 21 February 2019

ChemEngDayUK Edinburgh, 8–9 April Call for abstracts deadline is 31 January. https://milhostech.com

Hazards 29 BIRMINGHAM, 22–24 MAY 2019 Hazards 29 is IChemE’s annual process safety conference, the leading event of its kind in Europe. Covering every major aspect of process safety, Hazards 29 will share good practice, latest research and lessons learned, providing essential insight into how to manage and reduce risk effectively, and helping to make good practice common practice. Registration opens December 2018. www.icheme.org/hazards29

IChemE Global Awards 2019 TBC, 7 November 2019 Opens for entries March 2019. Entry deadline is 28 June. The Awards will be presented on 7 November 2019. www.icheme.org/awards

Advances in Process Automation and Control Manchester, TBC November 2019

Imperial College will host a tour of its carbon capture pilot plant, for IChemE members. www.icheme.org/pilot-plant-tour

Our biannual process automation and control conference comes to Manchester in 2019. Register your interest at [email protected]

north west engineering excellence awards manchester, 29 march 2019

ONLINE

Evening dinner event, organised jointly by IChemE’s North West Member Group, and IMechE. Closing date for all bookings is 1 March 2019. [email protected]

Glycerol to Green Chemicals 13 december 2018 The webinar will discuss the development of a sustainable green process for the production

of glycidol from glycerol, the byproduct of biodiesel production. www.icheme.org/glycerol-green-chemicals

Using Big Data in the Chemicals Sector 17 december 2018 This webinar will review and explain the history and evolution of data volumes, storage and handling in the chemicals sector since the early 80s. www.icheme.org/cape-big-data

Water Special Interest Group AGM 19 december 2018 Water SIG’s AGM will take place using the online facility GoToWebinar. All are welcome to attend, but only Water SIG members can vote. www.icheme.org/water-agm-2018

Addressing Engineering Challenges in Process Manufacturing with Descriptive and Predictive Analytics 16 january 2019 A one-hour webinar from the IChemE Process Management and Control Special Interest Group. www.icheme.org/ addressing-engineering-challenges

Major Trends in Process Automation 18 february 2019 Harry Forbes of ARC Advisory Group will present and discuss the major trends in the global process automation market. www.icheme.org/pmc-major trends

www.icheme.org/lpb www.icheme.org/lpb

Loss Prevention Bulletin Loss Prevention Bulletin Losssource Prevention Bulletin The leading of case in process safety safety The leading source of studies case studies in process For more information or tosource take out your subscription contactin process safety The leading of out case For more information or to take yourstudies subscription contact +44 (0)1788 534470 or [email protected]

+44 (0)1788 534470 or [email protected]

For more information or to subscribe contact [email protected] DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 60

tce.929.60.indd diary DG.indd 6062

13:45 06/12/2018 16:36

The Chemical Engineer courses FOR A FULL LIST VISIT WWW.ICHEME.ORG/COURSES UNITED KINGDOM & EUROPE Human Factors Alumni Edinburgh, 6 FEBRUARY 2019 www.icheme.org/human-factors-alumni

HAZOP LEADERSHIP AND MANAGEMENT RUGBY, 12–14 FEBRUARY 2019 www.icheme.org/hazop-leadership-uk

Layer of Protection Analysis (LOPA) RugbY, 19 FEBRUARY 2019 www.icheme.org/lopa-uk

Effective Alarm Management Leeds, 19 FEBRUARY 2019 www.abb.com/uk/consulting/training

HAZOP STUDY FOR TEAM LEADERS AND TEAM MEMBERS RUGBY, 26–28 FEBRUARY 2019 www.icheme.org/hazop-team-uk

FUNDAMENTALS OF PROCESS SAFETY MANCHESTER, 4–8 MARCH 2019 www.icheme.org/process-safety

Chemical Reaction Engineering Rugby, 5 MARCH 2019 www.icheme.org/reaction-engineering

Pressure Relief Liverpool, 12 MARCH 2019 www.abb.com/uk/consulting/training

Practical Aspects of ATEX/ DSEAR Compliance Success Southampton, 12 MARCH 2019 https://bit.ly/2QkppaD

LAYER OF PROTECTION ANALYSIS RUGBY, 12–13 MARCH 2019 www.icheme.org/lopa-uk

Expert Hazard Awareness Spadeadam, 26 MARCH 2019 Chemical Engineering for Scientists Rugby, 2 APRIL 2019 www.icheme.org/scientists

IChemE Forms of Contract London, 2 APRIL 2019

www.icheme.org/organisational-performance

HAZOP Leadership and Management Ireland, 10 APRIL 2019

HUMAN FACTORS IN DESIGN EDINBURGH, 4–5 DECEMBER 2019

www.icheme.org/hazop-leadership-ireland

HAZOP LEADERSHIP AND MANAGEMENT RUGBY, 9–11 APRIL 2019

www.icheme.org/human-factors-design

AUSTRALASIA & SE ASIA

www.icheme.org/hazop-leadership-uk

Hazard Study Leader Billingham, 29 APRIL 2019

www.abb.com/uk/consulting/training

LAYER OF PROTECTION ANALYSIS RUGBY, 7–8 MAY 2019 www.icheme.org/lopa-uk

Layer of Protection Analysis (LOPA) Ireland, 9 MAY 2019 www.icheme.org/lopa-ireland

HAZOP STUDY FOR TEAM LEADERS AND TEAM MEMBERS RUGBY, 14–16 MAY 2019

Managing Human Factors – module 1 Sydney, australia, 27 FEBRUARY 2019 www.icheme.org/human-factors-module-one

Process Safety Leadership and Culture Auckland, New Zealand, 7 MARCH 2019 www.icheme.org/safety-leadership

Project Finance Melbourne, Australia, 20 MARCH 2019 https://bit.ly/2QdOLah

Energy Cost Reduction Brisbane, Australia, 21 MARCH 2019

www.icheme.org/hazop-team-uk

www.icheme.org/energy-efficiency-australia

Process Safety Leadership and Culture London, 16 MAY 2019

Fundamentals of Process Safety Perth, Australia, 8 APRIL 2019

www.icheme.org/safety-leadership

What Engineers Need to Know About Contracts Rugby, 22 MAY 2019 www.icheme.org/contracts

HAZOP LEADERSHIP AND MANAGEMENT RUGBY, 4–6 JUNE 2019

www.icheme.org/hazop-leadership-uk

www.icheme.org/process-safety-aus

Bulk Solids Handling for Chemical Engineers Perth, Australia, 1 MAY 2019 www.icheme.org/bulk-solids-handling

HAZOP Leadership and Management Brisbane, Australia, 7 MAY 2019

Human Factors 9.2 Edinburgh, 5 JUNE 2019

www.icheme.org/hazop-leadership-uk

MANAGING HUMAN FAILURE EDINBURGH, 5–6 JUNE 2019

www.icheme.org/human-factors-module-two

www.icheme.org/human-failure

Chemical Engineering for Other Engineers Rugby, 11 JUNE 2019 www.icheme.org/chemical-engineering

Asset Integrity Management Rugby, 16 JUNE 2019

Managing Human Failures – module 2 Brisbane, Australia, 22 MAY 2019 Layer of Protection Analysis (LOPA) Perth, Australia, 3 JUNE 2019 www.icheme.org/lopa-aus

Layer of Protection Analysis (LOPA) Melbourne, Australia, 6 JUNE 2019 www.icheme.org/lopa-aus

www.icheme.org/asset-integrity

www.icheme.org/forms-of-contract

Area Classification Edinburgh, 2 APRIL 2019

FUNDAMENTALS OF PROCESS SAFETY EDINBURGH, 24–28 JUNE 2019 www.icheme.org/process-safety

www.abb.com/uk/consulting/training

https://bit.ly/2AXYSW7

STRENGTHENING ORGANISATIONAL PERFORMANCE EDINBURGH, 18–19 SEPTEMBER 2019

www.icheme.org/managing-human-factors

www.icheme.org/human-failure

https://bit.ly/2PlGiMQ

Practical Aspects of ATEX/ DSEAR Compliance Success Dublin, 2 APRIL 2019

MANAGING HUMAN FACTORS EDINBURGH, 3–4 APRIL 2019

ENGINEERING PROJECT MANAGEMENT RUGBY, 9–10 JULY 2019

www.icheme.org/project-management

Comprehensive Explosion Science Rugby, 18 JUNE 2019

www.icheme.org/explosion-science

SOUTH AFRICA HAZOP Leadership and Management Boksburg, 18 MARCH 2019 www.icheme.org/hazop-leadership-south-africa

Fundamentals of Process Safety (FOPS) Management Boksburg, 12 MAY 2019 www.icheme.org/process-safety-south-africa

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 61

diary DG.indd 61

06/12/2018 16:36

The Chemical Engineer jobs TO APPLY ONLINE VISIT JOBS.THECHEMICALENGINEER.COM, TO ADVERTISE CONTACT FREDDIE RICHARDSON AT MEDIA SHED, +44 (0)20 3137 8583, [email protected]

Plant Manager PROCESS ENGINEER HANTS

£33 TO £42,000 PA + BENEFITS GAS PRODUCTION/HYDROCARBONS

Our client, owned by an international energy major, operates the largest onshore gas storage facility in the UK; a top tier COMAH regulated operation that involves complex production, processing and storage facilities. The Process Engineer is accountable for supporting the optimisation of existing systems and the design of new processes across the company’s assets. The job holder will monitor plant trends with a view to trouble shooting and debottlenecking exercises, undertake process design work for plant modifications (including minor and major projects)in accordance with company, national and international engineering standards, provide process support during commissioning, input into COMAH reviews and HSE activities including Hazops, Hazids and environmental protection and process safety studies, liaise with maintenance, customers, engineering, production and subsurface teams on process requirements and performance forecasts, update the as-built status of key engineering drawings and documents etc. Candidates are likely to be working toward Chartered status, have an understanding of the engineering involved in oil and gas production/hydrocarbons and offer experience of having worked as part of a multi-disciplinary team in conceptual, FEED & detailed design projects in the energy industry.

For an initial confidential discussion about these roles, please call Mark Stracey at MSR on 01303 812433 or simply email a Word cv and a brief covering letter to [email protected]

We require an experienced Plant Manager to run our refinery based in Stoke on Trent. Using vacuum distillation, the refinery processes circa 40,000 tonnes per annum of waste automotive lubricants to produce gasoline; diesel; base oil; and a bitumen substitute. It employs a mature and successful team of 30 people. The Plant Manager will report directly to the Managing Director and will be responsible for all day-to-day plant activities – being Health, Safety and Environment; Production; Quality Control of Feedstock; Refinery Production (and Maintenance) whilst liaising with our Commercial Department as to Product Sales and Distribution. Further interest is provided by project management of a major investment that will double refinery capacity over the next two years. Applicants should hold a Degree in Chemical Engineering and have at least 10 years experience in industry with specific knowledge of distillation. Whelan Refining Limited is a successful and expanding, family owned and run business that provides a stimulating and enjoyable working environment. The successful applicant will be expected to live within 20 miles of the refinery and will be provided with relocation expenses to supplement a generous salary package.

Please apply in writing to: John Whelan, Whelan Refining Limited, Sneyd Hill, Burslem, Stoke on Trent, ST6 2DZ. Email: [email protected]

Mark Stracey Recruitment operates as both an employment agency and employment business

Representative of recruitment advertisers on thechemicalengineer.com

Mark Stracey Recruitment

JOBS.THECHEMICALENGINEER.COM DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 62

tce.930/31.62.indd 2

06/12/2018 13:02

AZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HA DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD AZARDS HAZARDS HAZARDS HAZARDS HAZARDSproducts HAZARDS HAZARDS HAZARDS HA The Chemical Engineer ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ VISIT WWW.THECHEMICALENGINEER.COM ADVERTISE CONTACT IAN HARTLEYHAZARDS AT MEDIA SHED, HAZARDS +44 (0)20 3137 8581, [email protected] HAZARDSTOHAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ AXFLOWHAZARDS HAZARDS HAZARDSMETTLER TOLEDO DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD ZARDS HAZARDSALMATEC HAZARDS HAZARDS HAZARDS REACTIR 702L HAZARDS HAZARDS HAZARDS HAZ MM SERIES AODD PUMP DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD AxFlow have introduced the new MM SeriesHAZARDS of AODD pumps from Almatec. MM Series pumps have been ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA designed specifically HAZARDS to meet the standards, regulations and operational requirements that govern ZARDS HAZARDStheHAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ food and beverage industry. Using food-grade wetted materials and construction HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H that provides easy cleaning, the pumps also feature soft redirections without rotating parts and shaft DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD seals in the product chamber. This design feature, when combined with the pump’s gentle displacement principle, results ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA in a pumping solution that is ideally suited for a wide variety of food and beverage applications. HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H The MM Serie’s material and design enable CIP and SIP capabilities. With diaphragms and ballHAZARDS valves also comply with HAZARDS EC1935/2004. In addition,HAZARDS HAZARDS HAZARDS HAZARDS HAZ ZARDS PTFE HAZARDS the pumps are ATEX conforming according to the 2014/34/EU directive. DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS FOR MORE INFORMATION CONTACT: HAZARDS HAZARDS HAZARD FOR MORE INFORMATION CONTACT: +44 (0) 1753 255 600; WWW.AXFLOW.CO.UK +44 (0) 116 234 5095; [email protected];HAZARDS WWW.MT.COM ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H AZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HA In association with theHAZARDS Mary Kay O’Connor Process SafetyHAZARDS Center ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA 22–24 May 2019, Birmingham, UK HAZARDS HAZARDS HAZAR RDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD JoinHAZARDS us at our annualHAZARDS process safety HAZARDS conference AZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HA ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA Hazards 29 HAZARDS will share goodHAZARDS practice, latestHAZARDS developmentsHAZARDS and lessons learned in process ZARDS HAZARDS HAZARDS HAZARDS HAZ safety, promoting a continous focus on safer operations and helping to make good HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H ZARDS HAZARDS HAZARDS practice common practice.HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD Covering every major aspect of process safety, it will bring together hundreds of ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ practitioners from around the globe,HAZARDS keen to learn from others’ experiences, stayHAZARDS HAZARD DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS up-to-dateHAZARDS with good practice, and network with their peers. ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ HAZARDSFind HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H out more andHAZARDS register: DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDSISC HAZARDS HAZARDS HAZARD www.icheme.org/hazards29 HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS H ARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZA RDS HAZARDS HAZARDS HAZARDS HAZARDS The Chemical Engineer DECEMBER 2018/JANUARY 2019 | HAZARDS | page 63 HAZARDS HAZARDS HAZAR ZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZ DS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARD AZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS HA tce.930/31.63 Products.indd 62 06/12/2018 13:05 METTLER TOLEDO’s ReactIR enables scientists to study reaction progression over time, providing highly specific information about initiation, endpoint, conversion, kinetics, mechanism, and pathway. A real-time, in situ mid-infrared system, ReactIR directly follows the concentration of key reaction species as they change during the course of the reaction. This provides in-depth understanding for scientists as they improve the research and development of chemical compounds, synthetic routes, and chemical processes.

ReactIR 702L uses solid-state cooling technology to deliver best-in-class performance without the need for liquid nitrogen. By eliminating hazardous experimental setup and repetitive Dewar refills, scientists can monitor chemistry with ease over extended periods. Find out more about the ReactIR 702L today by visiting WWW.MT.COM/REACTIR

Hazards29 IChe

m

E

t

y

re

Safet

Ce

n

RESIDuE the STUFF LEFT OVER AT THE END 1

1

2

3

5

9

4

6

7

8

The Chemical Engineer

10

9

11

12

13

14

christmas crossword

15

15 18

5

17

16

17

18

19

It’s the most cry pti cal time of the yea r! Ding dong, ding dong! A big tha nk s to Reg Tan for his festive cry ptic crossword . Email your comple ted grid to [email protected] rg by 11 Januar y for a chance to win £50 worth of Amazon vouchers. Instructions: The sec ondary par ts of starre d* clues entail a redundant letter, which must be rem oved before entering into the gri d to fit the def initio n. The same letter is involved in all starred clues.

20 21

22

24

Taking

23

25

We are all responsible for

27

26

27

tark when Who needs Tony S ers? you have research t from Sellafield

n a contrac of Bristol has wo of wearable THE University feasibilit y study UK to carry out a ate ov Inn d an Ltd issioning workers. nuclear decomm ll consider technologies for , researchers wi ero rh suited supe d improve Inspired by the an rs rke protect wo e robotic suit to an Iron-Man typ awareness. on and their situational arable exoskelet incorporate a we uld wo it su terials. e ma Th from composite covering made dy bo e tiv techtec er pro oth a capabilit ies as lude Jar vis-style ment ve mo e It might even inc ey ject include iewed by the pro ics, on ctr ele nologies to be rev le ab int worker fat igue; pr t tec de r tte be to improve track ing, nted systems to g; and hand-mou rin wi it su into avoid terials. ion and nuclear ma suits. detection of radiat wear air-fed PVC issioning workers radist Current ly, decomm ain ag better shielding its could provide ess str l ca ysi The imagined su ph and reduce to decontaminate, rly ea in ck ba ation, be easier ort pect to rep e researchers ex rk is wo r the on the wearer. Th fur if termine Sellafield will de ype. 2019. A rev iew by a work ing protot of nt me lop ve de ing lud inc d, won’t nte warra fans – workers ate disclaimer for their t ou But, an unfortun they’re carry ing oured hero when l’s rve Ma ble look like the arm actually resem the real suit won’t nuclear feats, as imaginings.

Ac ro ss

1.* 9, bar the parasi tes (6) 4. Mazy centre in Ara b culture? (6) 9,5. Free spaces once bound in 16-dn (4,6) 10. Substitute team member in tortuous way... (10) 11. …undoing faults in game (6) 12.* Relax, get instan t hamper (8) 13. State of a pot boi ling with zero chang e? Yes. (9) 15. Time to end e-filin g returns (4) 16. Misrepresented recital piece (4) 17. Roman dev ice to measure inside air pressure? (9) 21. Philosophical sum mary (8) 22. Easy transfer of 15 across? (6) 24.* Islander fashio ned a hot air contai ner (10) 25.* Wood fuzz (4) 26.* Left after no kic kback in Cit y (6) 27. Solvent for noble gases (6)

Do wn 1. Impromptu music

test? (3,4) 2.* Let this be our tre at! (5) 3.* 18 nearly all are narrow-minded (7) 5. See 9-ac. 6. Fruit and veg tra nsporter with booze lands in hospital! (9) 7. Convert transitio n metal 23 (7) 8.* Could these lead to climatic posers at sea? (13) 14. Exceed gy m hou rs, by 9 showers! (9) 16. Sign on vacant rep ositor y or one wellstocked? (7) 18. Assault of the cri minal type (7) 19. Backtalk enters different orbit (7) 20. Tribal happening around island uprisin g (6) 23. Ride with 15 seq uential stages (5)

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 64

residue930 DG.indd 64

06/12/2018 15:25

The Chemical Engineer suppliers & services VISIT WWW.THECHEMICALENGINEER.COM TO ADVERTISE CONTACT IAN HARTLEY AT MEDIA SHED, +44 (0)20 3137 8581, [email protected] CHEMICAL RESTRAINT LININGS

VALVE ACTUATION SPECIALISTS

HOSE, VALVES & COUPLINGS

PROKEM Supply materials for the most aggressive of chemicals & also offer installations to the following

AVS, a UK ISO9001 approved quality supplier of valves specialising in pneumatic and electrically actuated ball and butterfly valves, and valve accessories. Quality valve and actuated project solutions for most industrial process applications. Specialist valve and actuator products offering exceptional chemical and corrosion resistance and user-friendly time saving installation.

A leading manufacturer and supplier of hose assemblies, valve and coupling products providing ‘the right connection’ for companies in a broad range of industries.

+44 (0) 330 053 5750 [email protected] ACTUATEDVALVESUPPLIES.COM

+44 (0) 1772 323529 [email protected] WWW.DIXONEUROPE.CO.UK

FLOORS, BUNDS, SUMPS, CHANNELS, TANKER UNLOADING BAYS.

SUPERVISION SERVICE FOR ACID RESISTANT TILING SCREEDS MULTI COATINGS & GRP LININGS +44 (0) 1142 899281 +44 (0) 771 385 6433 [email protected] WWW.PROKEM.CO.UK

Dixon offers specialised support and bespoke engineered solutions from concept, to design, through to installation providing; hose fittings, couplings, hose assemblies, valves and related accessories.

Peter Kendrick Director

PROCESS SAFETY t +44 (0) 114 289 9281 m +44 (0) 771 385 6433 e [email protected] www.prokem.co.uk

ENGINEERING DESIGN-PROJECT & CONSTRUCTION

60 Main Road Holmesfield Dronfield Derbyshire S18 7WT

Safety Engineering Solutions is a professional process safety engineering consultancy providing flexible, competitively-priced consulting/engineering services within a wide range of challenging industries and environments, both onshore and offshore. We specialise in Process Safety Management; HAZID HAZOP/SIL; Bowtie development; consequence modelling; firewater demand/network hydraulic analysis, hazardous area classification; and flare radiation/dispersion assessment.

+44 (0) 7808 889684 [email protected] WWW.SAFETYENGINEERINGSOLUTIONS.COM

STEAM

Ultrasonic Flowmeter for

PROCESS CONTROL

TLV produces steam traps, condensate recovery pumps, pressure reducing valves and other steam-related equipment.

(2ml-15L/min)

TLV also We also offer consulting and engineering services. TLV consulting, engineering and service activities are designed to find the best solutions to increase productivity, maximize energy savings, improve quality and promote environmental conservation.

process TM

TITAN ENTERPRISES LTD

Coldharbour Business Park, Sherborne, Dorset DT9 4JW. UK

www.flowmeters.co.uk

TLV. EURO ENGINEERING UK LTD +44 (0) 1242 277 223 [email protected] WWW.TLV.COM

ICHEME PUBLICATIONS

Advertise year round to more than 32,000 process & chemical engineers for just £495+VAT

IChemE Online Store We have a wide variety of products available on our online store: • • • • • •

CALL IAN HARTLEY ON +44 (0) 207 183 1815 TO BOOK YOUR SLOT

Forms of Contract BP Process Safety Series A range of books Conference proceedings Case studies Online training

[email protected] WWW.ICHEME.ORGSHOP

DECEMBER 2018/JANUARY 2019 | The Chemical Engineer

tce.930/31.IBC suppliers and services.indd 62

06/12/2018 13:05

Take a closer look at how we optimise space to innovate in manufacturing processes

wspfortheture.co.uk

tce.930/31.OBC.indd 2

06/12/2018 13:04