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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.”
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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
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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
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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.”
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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.
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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.
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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.
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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.
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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
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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
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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.
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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.
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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
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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
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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!
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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.
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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
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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
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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
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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.
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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
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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.
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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.
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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.
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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.
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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
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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.”
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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
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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
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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 ■■
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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
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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
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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
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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
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www.icheme.org/energy-efficiency-australia
Process Safety Leadership and Culture London, 16 MAY 2019
Fundamentals of Process Safety Perth, Australia, 8 APRIL 2019
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What Engineers Need to Know About Contracts Rugby, 22 MAY 2019 www.icheme.org/contracts
HAZOP LEADERSHIP AND MANAGEMENT RUGBY, 4–6 JUNE 2019
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Bulk Solids Handling for Chemical Engineers Perth, Australia, 1 MAY 2019 www.icheme.org/bulk-solids-handling
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DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 61
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The Chemical Engineer jobs TO APPLY ONLINE VISIT JOBS.THECHEMICALENGINEER.COM, TO ADVERTISE CONTACT FREDDIE RICHARDSON AT MEDIA SHED, +44 (0)20 3137 8583,
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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.
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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.
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JOBS.THECHEMICALENGINEER.COM DECEMBER 2018/JANUARY 2019 | The Chemical Engineer | page 62
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