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| CHEMICAL INDUSTRY JOURNAL |
www.chemicalindustryjournal.co.uk
| foreword |
Welcome It’s time for meaningful change Karen Southern Editor
Editor Karen Southern karen.southern@distinctivegroup.co.uk
Design Distinctive Media Group Ltd, 3rd Floor, Tru Knit House, 9-11 Carliol Square, Newcastle, NE1 6UF Tel: 0191 580 5990 distinctivegroup.co.uk
Advertising Distinctive Media Group Ltd, 3rd Floor, Tru Knit House, 9-11 Carliol Square, Newcastle, NE1 6UF Tel: 0191 5805990 David Perratt Business Development Manager email: david.perratt@distinctivegroup.co.uk Tel: 0191 5805471 distinctivegroup.co.uk
We all know times are tough so let’s not dwell on that. This issue looks at trends and technologies that focus on the bigger picture: creating a more sustainable and stable future for us all. ACHEMA 2022 is helping nudge the industry in the right direction. Later this month, the Frankfurt-based show for the global process industry puts the spotlight on the industry’s current ‘hot potatoes’ – digitilisation, supply chains and decarbonisation – through debate, presentations and practical demos. A brief preview of the event is included in this issue. Graphene doesn’t get a lot of coverage in general chemical news, so speciality chemicals company William Blythe Ltd deserve a special mention for their unique graphene oxide product. Over the past couple of years, the brilliant team at this Lancashire-based firm has quietly scaled up what is thought to be one of the world’s largest production capacities to meet growing demand. Initially set up in 1845 to produce dyestuffs and commodities, the company is now a proven manufacturer of advanced materials for use in many new and emerging applications, so it’s a resounding ‘well done’ to them.
Distinctive Media Group Ltd or Chemical Industry Journal cannot be held responsible for any inaccuracies that may occur, individual products or services advertised or late entries. No part of this publication may be reproduced or scanned without prior written permission of the publishers and Chemical Industry Journal.
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Meanwhile, the Chemical Business Association (CBA) is backing a string of initiatives to close the worrying skills gaps permeating the whole industry. As chief executive Tim Doggett points out, recruitment is just one step in the process. Mentoring, training and development are crucial too, and as such the CBA has thrown its considerable support behind schemes to promote careers in chemicals and logistics. ‘It’s time to do things differently when it comes to distribution’, says Karsten Smet of ACI Group, in his thought-provoking feature. He believes that adding value at every touchpoint is key to tackling our supply chain challenges, with technical innovation about to blur the lines between distribution and IT. And finally a recent member survey from the Chemical Industries Association (CIA) reveals that while the UK industry has shown a successive eighth quarter of growth, this is unlikely to continue into the third quarter of 2022. It’s time for the new Government to boost competitiveness and ease energy costs, is the rallying cry from Chief Executive Steve Elliott. Will our latest political influx have the appetite to support meaningful change? We’ll have to wait and see.
| CHEMICAL INDUSTRY JOURNAL |
| contents |
AI for plant monitoring: platform or purpose-built?
features
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30
Taking nanotechnology from lab to market: a graphene oxide case study
Oligonucleotides: the journey so far
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| CHEMICAL INDUSTRY JOURNAL |
| contents |
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contents www.chemicalindustryjournal.co.uk
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welcome
4-5
Contents
10-11
agrichemicals
/
issue 27
Scientists at the University of Birmingham have invented a method to encourage bacteria to form growth-promoting ecosystems.
16-19
innovation The team at William Blythe Ltd explains how graphene oxide production has been scaled up to meet increased global demand for the novel material.
30-31
big interview Seamus White, Bachem business development manager, tells Chemical Industry Journal how oligonucleotide therapeutics could simplify the work of pharma and biotech companies.
34-35
INDUSTRY 4.0 AI for plant monitoring: platform or purpose-built? Andrew Normand, UptimeAI partnership lead at Encora Energy, discusses which approach could be the right fit for your business.
40-41
software automation Collecting, analysing and extracting value from data is the next step in optimising industrial processes. But it’s still a sadly underutilised process, says Jason Chester, Director of Global Channel Programs, InfinityQS.
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distribution & Logisitics Thrive, not survive: Adding value at every touchpoint is key to tackling supply chain challenges.
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Industrial automation makes way for information automation
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| CHEMICAL INDUSTRY JOURNAL |
| news |
ACHEMA 2022: addressing digitalisation and sustainability ACHEMA 2022, which takes place in August, is regarded as a world-leading show for the process industry. In addition to the transformation towards a climate-neutral chemical industry and the perennial topic of digitalisation, the current global political situation also poses massive challenges for the industry. Which technologies can be used to achieve defossilisation? How to secure and enhance regional and global supply chain networks? And what hurdles must be overcome in the digitalisation of the industry? As a forum for chemical engineering, process engineering and biotechnology, ACHEMA 2022 will investigate and debate potential answers to these questions and more. Europe aims to become climate-neutral by 2050. In line with this target, the chemical industry is working on technologies to achieve this goal. What are the opportunities, challenges, and obstructions? How do we shape the necessary political framework and incentives? Which financial instruments are required? These questions will be addressed at the opening event ‘Climate-Neutral Chemical Industry’ on 22 August 2022 on the first day.
GREEN INNOVATION ZONE Five areas in particular are in the spotlight: climate-neutral production, circular economy, industrial water, sustainable chemistry, bio-based economy. “The process industry will have to electrify its facilities across the board and use hydrogen as an energy source in the medium term if it wants to live up to its responsibility for sustainable value creation,” Frank Jenner, of EY, the main green innovation partner, is quoted as saying. “The industry is already going to great lengths and it’s a huge challenge, but it can be done.”
DIGITAL HUB AND DIGITAL LAB The topic of digitalisation has finally claimed a top spot on the agenda of the process industry, with new exhibition group Digital Hub which, as the name suggests, is the central meeting point for digital specialists. The Digital Lab Action Area is presented as the smart lab of tomorrow’ with manufacturers demonstrating crossmanufacturer digitalisation solutions using relevant practical examples. The spectrum ranges from Cobotassisted work processes for sample preparation and analysis, user-oriented process control with Laboratory Execution Systems, to horizontally and vertically connected, modularly adaptable equipment solutions. Innovative software and device solutions are supported by the Laboratory & Analytical Device Standard (LADS) for OPC UA.
ABOUT ACHEMA ACHEMA takes place every three years in Frankfurt, and covers all aspects of the process industry from laboratory equipment, pumps, and analytical devices to packaging machinery, boilers and stirrers to safety technology, materials, and software for the chemical, pharmaceutical and food production industries. This year’s event runs between 22 – 26 August 2022 in Frankfurt am Main. More at achema.de
Subscribe for free! Simply use the link below and get all the latest chemical industry news – either digitally or in print. www.chemicalindustryjournal.co.uk/subscribe
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| CHEMICAL INDUSTRY JOURNAL |
| lauda |
lauda provide precise heating and cooling solutions LAUDA – Experts In Thermal Control And Measurement Providing Innovative Solutions For Thermal Process Control, Chilled Water Applications, Water Baths, Freezers, Incubators, Shakers, Stills, Tensiometers, Viscometers And Contact Angle Measurement. LAUDA continues to provide an expanding range of feature-rich, future proof solutions with energy efficiency and connectivity front of mind, serving a diverse range of industries including chemical, pharmaceutical, biotechnology, oil and gas, composites, automotive, aerospace food & beverage, brewing, digital printing, laser and beyond. LAUDA’s new range of water chillers has been designed not only to comply with the new Eco-design directive, but to surpass it through the innovative use of variable speed modules that automatically reduce their duty cycle in line with the cooling demand hence reducing energy consumption and running costs, giving a tangible return on investment for the user, whilst ensuring full compliance with the latest regulations on refrigerant (fluorinated) gases. Further portfolio expansion delivers the new LAUDA ‘Versafreeze’ ultra-freezers, (deep-freeze storage down to -85°), and higher power ‘Integral’ process circulators, (process control from -90 to 320°C with >25kW of cooling @20°C), with pressure overlay options to increase the working range of water / glycol up to 140°C. Furthermore, for applications requiring customised solutions tailored to individual requirements, we offer a made-to-measure design service using a long-established
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and highly skilled team. Project engineering is a core competence of LAUDA and using the modular engineering approach we can design and scale a system specifically matched to the application needs. With the capability to provide accurate heating and cooling in the range -150 to +550 °C using a variety of proven modules including heat transfer systems, process cooling systems, secondary circuit systems, fired heaters and molten salt plants, we are able to provide unique, costeffective solutions unparalleled by others. Beyond temperature control, LAUDA has a well-established suite of solutions for measuring viscosity and surface/ interfacial tension aimed at the development of polymers, oils, and surfactants. We look forward to hearing from you. Contact details: T: +44 (0)1780 243118 E: info@lauda-technology.co.uk www.lauda-technology.co.uk www.linkedin.com/company/lauda-technology-ltd www.facebook.com/LAUDA.UK/ https://twitter.com/lauda_uk
| CHEMICAL INDUSTRY JOURNAL |
| news |
New technology electrifies key processes in chemicals New Oxbridge-developed tech could cut 30 per cent of industrial CO2 emissions. Oxbridge-developed technology uses electrification to remove the need for burning of fossil fuels in high-emitting industrial processes. Powered by electricity from renewable sources, the RDH is the only process heating technology in the world that can cut up to 30% of industrial CO2 emissions and over 7% of global CO2 emissions annually, according to Coolbrook, the company behind the technology. The Roto Dynamic Heater (RDH) technology has been successfully tested in a pilot project in Finland and will be available for commercial use at scale in 2024. Construction materials company CEMEX was the first to announce it will use RDH to reduce CO2 emissions from its cement production. This is in addition to Coolbrook’s existing partnerships with ABB and Shell.
HOW THE TECHNOLOGY WORKS Industrial CO2 emissions originate primarily from three main sectors: petrochemicals and chemicals, iron and steel and cement production. The RDH, powered by electricity from renewable sources, can achieve process temperatures of up to around 1700ºC with high energy efficiency, meaning it can be used in processes that were impossible to electrify up until now, including in the highest-emitting industrial sectors. Its compact size means it can also be retro-fitted to existing facilities and help accelerate CO2 emission reduction investments.
The technology has been in development for over a decade and marks the second major technology developed by Coolbrook after its Roto Dynamic Reactor (RDR) which can be used to electrify the steam cracking process in the petrochemical industry. Ilpo Kuokkanen, Executive Chairman of Coolbrook, said: “Today marks the beginning of a new industrial era. Coolbrook has set a target to build a committed and comprehensive ecosystem around its revolutionary technology to commercialise it as soon as possible. Together with ABB, CEMEX, Shell and our other partners in industry, academia, public sector and among key decision-makers we can roll out this revolutionary technology and achieve significant emission reductions in the most energy and CO2 intensive industrial processes that have been considered impossible to electrify.” Roberto Ponguta, CEMEX vice-president of Global Operations, Technical and Energy, said: “The electrification of the production process is an important step towards fully decarbonising our cement operations. We are constantly looking for the best technologies and relationships to meet our Net Zero CO2 target. Our cooperation with Coolbrook will support us in achieving this ambition.” Coolbrook Ltd. is a technology and engineering company which develops rotating technology combining space science, turbomachinery and chemical engineering to replace burning of fossil fuels across all major industrial sectors.
Together with ABB, CEMEX, Shell and our other partners in industry, academia, public sector and among key decision-makers we can roll out this revolutionary technology and achieve significant emission reductions in the most energy and CO2 intensive industrial processes that have been considered impossible to electrify. Ilpo Kuokkanen, Executive Chairman of Coolbrook
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| CHEMICAL INDUSTRY JOURNAL |
| news |
Sustainable bioplastics facility is world-first Work has started on the world’s first FDCA Flagship Plant in the Netherlands. Avantium’s bioplastics facility at Delfzijl will produce plant-based furandicarboxylic acid (FDCA), a key building block for many chemicals and plastics such as polyethylene furanoate (PEF), a fully recyclable plastic. It will be the world’s first facility to produce FDCA on a commercial scale, with a capacity of five kilotonnes per year. The project will be the commercial proof for future largerscale developments. The new facility is located near Avantium’s demonstration plant for plantMEG™ (monoethylene glycol) and its pilot biorefinery, producing glucose and lignin from non-food biomass. The area is a prime location for green chemistry in the Netherlands and aims to achieve a fully sustainable chemical industry by 2050. Avantium‘s latest initiative seeks to help shift the chemicals industry away from fossil resources and towards sustainable feedstocks, creating 50 highly skilled jobs in the process. Company CEO Tom van Aken said: “Avantium is proud to be the first company in the world that is constructing a commercial facility to produce FDCA, the key building block of PEF. “I strongly believe that PEF has the potential to become a major polymer to be used across many applications and markets worldwide, helping us on the path to a circular economy. We are pleased with the support of our partners for our FDCA Flagship Plant. Everyone can see how our plans for a commercial FDCA facility are becoming a reality.” Construction should be completed by the end of 2023, enabling the commercial launch of PEF from 2024 onwards. The bioplastics facility is being built in partnership with Worley, following on from their previous concept development and front-end engineering design collaboration.
Digging sustainable foundations: Tom van Aken, Mark Brantley, Cas Konig and Bas Blom.
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Worley has acquired a shareholding in Avantium in return for a €10 million equity investment with a risk-sharing mechanism over the EPC phase of the FDCA plant. They have also signed a technology cooperation agreement with Avantium and will deliver EPC services to develop the facility. Tom van Aken continued: “Avantium believes that the confidence in the project demonstrated by Worley and their substantial experience in scaling-up to industrial plants adds strength and credibility to Avantium’s technology and licensing proposition. Mark Brantley, Worley Group President EMEA and APAC, added: “We’ve worked with Avantium over the last years in the scale-up to commercial scale for its flagship facility and this marks an important milestone in the project as we evolve to the next phase.” The FDCA Flagship Plant is supported with a PEFerence Horizon 2020 grant awarded by Bio-based Industries Joint Undertaking (BBI JU) under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 744409.
| CHEMICAL INDUSTRY JOURNAL |
| agrichemicals |
Novel synthetic polymers could lead to greater crop yields Scientists at the University of Birmingham have invented a method to encourage bacteria to form growth-promoting ecosystems. This could be used to coat the roots of plant seedlings, and help create stronger, healthier plants, and higher crop yields in agriculture. In nature, the roots of seedlings form mutually beneficial relationships with communities of microbes (fungi, bacteria, viruses) in soil, and exchange nutrients, allowing both the plant and the microbes to flourish. This is particularly critical in the early stages of a plant’s life when the seedling is in a race against time to reach self-sufficient growth before the nutrients and energy stores in the seed run out.
Dr Tim Overton, an applied microbiologist from the University’s School of Chemical Engineering, and Dr Francisco Fernandez-Trillo from the School of Chemistry led a team to develop novel synthetic polymers that stimulate the formation of these bacterial communities, in a way that mirrors a natural process known as biofilm formation. A biofilm is a finely orchestrated community of microbes, supported by matrix of biological polymers that forms a protective micro-environment and holds the community together. The researchers worked jointly on a four-year project on how polymers interact with bacteria, which resulted in the synthesis of a group of acylhydrazone-based polymers.
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| CHEMICAL INDUSTRY JOURNAL |
| agrichemicals |
These new polymers were designed to act as an adhesive scaffold, “seeding” the formation of a microorganismpolymer complex to initiate and expedite biofilm formation. Once the biofilm is formed, the bacteria become a self-sufficient and self-organizing community, and produce their own matrix to allow the transmission of nutrients and water, and the discharge of waste products. The project was funded by Biotechnology and Biological Sciences Research Council (BBSRC) through their Midlands Integrative Biosciences Training Partnership. It involved PhD students Pavan Adoni and Omar Huneidi, who subsequently progressed research showing the polymers aggregate bacteria, and improve biofilm formation. Critically, they also showed the process is fully
“We envisage a more targeted approach that only treats the seed, so that when it germinates the bacteria are ready to grow in the safe harbour environment provided by a micro-organism polymer complex. “
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reversible, and the biofilm can be dispersed by changing the environmental conditions. The results of these experiments and further studies will be published in 2022. Pavan Adoni commented: “We anticipate that the polymer will ultimately be used as a seed coating, perhaps in conjunction with bacteria such as B. Subtilis, which is naturally present in soil, increases the stress tolerance of plants, and is currently used as a soil inoculant. We envisage a more targeted approach that only treats the seed, so that when it germinates the bacteria are ready to grow in the safe harbour environment provided by a micro-organism polymer complex. Ultimately this should result in stronger plants, which grow more quickly, and have greater resilience to disease.” University of Birmingham Enterprise filed a broadbased patent application covering the novel polymers, the method of forming the biofilm and the method of polymer cleaving, and its use to promote growth of a biofilm with any micro-organism including those that can produce or deliver chemical or biological molecules. The patent has now been licensed to specialist life science company PBL Technology, which invests in, protects and promotes emerging innovations from public research sources worldwide. In agriculture, PBL’s technologies include crop genetics, crop treatments, precision agriculture and promoters and R&D tools. Companies wishing to discuss potential applications, partnerships or co-development should contact Lars von Borcke, PBL Technology email: lars@pbltechnology.com.
| CHEMICAL INDUSTRY JOURNAL |
| news |
Growth continues, but concerns remain The latest survey of business confidence from one of Britain’s biggest manufacturing exporters shows a strong performance but concerns for the future remain. The second quarter survey of members of the Chemical Industries Association sees the chemical industry showing an eighth successive quarter of growth – however this performance is not expected to continue into the third quarter of 2022. Fifty chemical businesses, ranging from multi-nationals to SMEs located across the UK expect new orders, exports, and domestic sales to fall in the third quarter of the year as inflationary pressure on both households and businesses begins to erode demand. The Association’s Chief Executive, Steve Elliott, said: “I am encouraged to see that despite the persistent rises in energy, raw material, transportation, and labour costs, as well as a myriad of logistical challenges – the industry continued to grow in the second quarter of 2022. However, it is important to focus on the future. Our membership is extremely concerned about the next few months and the impact that could have on long term investment. “For example, we have been working with massive increases to our input prices for nearly a year now; previously such a problem would right itself after a very short period of time. The robust demand by customer industries for what our companies make has helped us deal with this.
“However, as consumer inflation approaches double digits and with producer inflation being at twice that level, orders from customers are beginning to reduce. Some of these challenges are global in nature, but there are measures that can be taken by a new Government to boost competitiveness and ease energy costs, such as action to remove the non-wholesale cost from industrial energy bills as well as preparing as best as we can to minimise any threat of energy supply disruption later in the year”. The CIA’s Head of Economics, Tom Warren, added: “Energy costs, the cost of labour, and raw material costs and shortages continue to be the four largest challenges facing the chemical industry. “Concerningly, all four challenges are felt by respondents to be worsening. Indeed, as inflation in the UK continues to rise, in June rising to 9.4%, a forty-year high, each of these challenges are being further compounded. The chemical industry needs this to be addressed to reduce the burdens facing the industry going into Q3”.
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| CHEMICAL INDUSTRY JOURNAL |
| epal |
Open pallet pooling – driving efficiency at a time of margin pressure Businesses across the world are struggling with a series of major crises in their supply chains, which are restricting availability and pushing costs up. Companies that supply goods, from food and drink to pharmaceuticals, can make savings and increase efficiency by making the right choice of pallet system. In the wake of COVID, supply chains around the world are facing an unparalleled challenge caused by a combination of several issues. These include a shipping crisis, which has severely restricted availability of containers in many regions and pushed prices up to unprecedented levels around the world; intense post-lockdown competition for resources to service pent-up demand; raw material price hikes and volatility; marked energy price rises; and, in Europe, increased admin, time and cost following the completion of Brexit at the beginning of 2021. The war in Ukraine has intensified these issues further. The situation has caused extreme pressure for businesses, requiring them to develop more adaptable and responsive strategies to cope with the changeable marketplace and, amid severe competition, squeezing their margins. Against this background, most companies are examining their operations to make them as efficient and straightforward as possible. This means looking for transparency and reliability from their supplier partners, seeking new approaches that allow them to maintain quality, while reducing costs and increasing their all-round efficiency. With logistics costs a major squeeze point, many businesses are investigating more financially effective ways of organising this part of their operations. This includes considering alternative supply chain models to buying pallets for transporting goods. Maximising efficiency in pallet use is an important cornerstone in a well-run supply chain - and closed and open pooling systems both create advantages for companies using them over outright purchase of the pallets. Closed pallet pooling is run by independent companies that own and manage a ‘pool’ of pallets, renting them to supply chain users and collecting, and maintaining and repairing them for continual reuse. In open pallet pooling, meanwhile, companies buy pallets, and they then remain an asset until they are resold to their customer as part of the transactions for the goods they are purchasing – or exchanged for an empty pallet of equivalent value on arrival at their destination. EPAL runs the largest open pallet pool in the world, which was founded in 1991 and now has more than 600 million EPAL Euro pallets and 20 million EPAL box pallets in circulation. Pallets are shared and reused within a network that consists of producers, manufacturers, distributors, retailers and other receiving locations, transporters, logistics service providers (LSPs) and service centres. The size of the pool underpins its success – as this drives efficiency and means that at most delivery locations in Europe, there will be empty EPAL pallets to exchange for those bringing in the goods. The system works by exchanging pallets between the goods recipient and EPAL load carrier, reducing the costs associated with reloading. EPAL supports this process with practical handling advice.
The pool also gives companies using it access to an international network of more than 1,500 licenced pallet repairers in more than 30 countries; so damaged pallets can be collected and reconditioned/repaired before they are returned for reuse in the supply chain. EPAL specifies repaired pallets ‘as new’, so a repaired, reused pallet guarantees the same strength - safe for loads of up to 1.25 tonnes -as a new one on its first trip. This is essential, particularly to users in high value supply chains, such as pharmaceuticals or alcoholic drinks. All new and reconditioned EPAL pallets are manufactured from sustainable timber sources and treated to ISPM15 certified plant heath levels as standard, making them legally compliant for post-Brexit movement between the EU and UK markets, and across all international borders. The simplicity of this open pooling allows logistics companies to focus on their core business and keep logistics low cost and straightforward. Meanwhile, the fact the open system has repair and reuse at its core make using it an important addition to companies’ sustainability efforts as they seek meet new regulatory requirements that encourage circular economic activity. These include the Extended Producer Responsibility Regulations (2024), and the UK 2050 net zero target and interim target of a 78 per cent reduction on 1990 levels by 2035. Added to these, pallets that are manufactured from wood are still the most economic option. While the current climate has pushed the price of timber up, other raw materials have seen price rises, too. This, together with the above advantages of the open pooling model will be a decisive factor for many goods businesses as they seek to drive efficiency and cost savings in the post-pandemic world. uk-irl.epal-pallets.org
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we are
circular economy
uk-irl.epal-pallets.org
| CHEMICAL INDUSTRY JOURNAL |
| innovation |
Taking nanotechnology from lab to market: a graphene oxide case study
The team at William Blythe Ltd explains how graphene oxide production has been scaled up to meet increased global demand for the novel material. WHAT IS GRAPHENE OXIDE? Graphene oxide (GO) is a derivate of graphene, the 2-dimensional material discovered at the University of Manchester by Nobel Prize winning scientists Andre Geim and Kostya Novoselov. Like graphene, GO is made up of a single layer of carbon atoms arranged in a 2D hexagonal lattice. This structure gives the material remarkable strength, thermal conductivity and sensing properties. In contrast to graphene, GO has oxygenated functional groups distributed across the ‘sheet’, which disrupt the delocalised electron structure and lead to greatly reduced electronic properties. These oxygen-containing groups do however enable greater functionality in dispersing the single layers across a range of systems, and can be functionalised to tune the hydrophilic properties.
MANUFACTURING GRAPHENE OXIDE The two most common manufacturing routes for GO are by electrochemical oxidation of solid graphite (e.g. graphite rods) and wet chemical oxidation of graphite powder. For scalability and reproducibility of consistent material, the latter process is desirable, and was the method chosen by the William Blythe chemists when the R&D work began in 2015. Coincidently, the first reported synthesis of GO or “graphic acid”, as it was stated in this paper, was published in 1859 by Benjamin Brodie [1], 14 years after William Blythe Limited was incorporated. Brodie’s method employed potassium chlorate and fuming nitric acid as the strong oxidiser & acid combination required to intercalate between the graphite layers and react with the delocalised electron structure. Over the years this method has been optimised in academia to improve its safety, resulting in the most common method now employed commercially, the Hummers method. This method utilised sodium nitrate and potassium permanganate in concentrated sulfuric acid to produce a GO material with a high oxygen content, an important property that correlates strongly with a high yield of single-layered GO.
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| CHEMICAL INDUSTRY JOURNAL |
| innovation |
4. Purification = nanomaterials can be difficult to purify through conventional methods as a result of their tiny size and in the case of GO, 2D sheet-like morphology. To combat these, a combination of R&D and Operations worked through the relevant hazard studies to ensure that the safest process was being pursued, worst-case scenarios analysed & mitigations implemented, and all occupational hazards taken into account during the plant design phase. This was all supported by the top tier COMAH site status and decade’s worth of experience the company has in safely handling hazardous chemistries. Another key enabler to scaling up the Hummers method is William Blythe’s on-site wastewater treatment plant, which is well equipped to handle the large quantities of acids and the oxidising agent by-products, ensuring a safe effluent stream. The team is now working on routes to recycle the sulfate waste in existing processes, in pursuit of more circularity within the manufacturing site. All of the above led to the development of a safe production route, but the last remaining challenge was to ensure the high purity remained from lab to plant. Utilising internal know-how and significant R&D efforts, a scalable purification method was developed to produce a highquality material with very low batch to batch variability.
APPLICATION & COMMERCIALISATION For those informed in the graphene space, you’ll know it has been researched across hundreds of different applications. Given the hype, William Blythe has been careful in selecting key application areas for internal developments of its material. Whilst the William Blythe GO has been used in gas sensing [2], CO2 capture [3] and biomedical [4] applications in academia, the company has also explored it’s use in water purification and energy storage in commercial UKRI projects. The current drivers for the scale-up to a 50-tonne/year capacity are in filtration and polymer additive applications, and the company continues to work with partners in other areas to help commercialise this nanomaterial.
REFERENCES 1. Royal Society, 1859, 149, pp.249-259 2. Carbon Trends, 2021, 5 (100123), pp.1-7 3. Advanced Functional Materials, 2020, 30 (40)
TRANSFER FROM LAB TO PLANT
4. Dental Materials, 2019, 35(11), pp.1614-1629
As commercial demand for William Blythe GO increased in 2020, the decision was made to transfer the optimised lab method to the next stage in scale-up. Early in the process, the operations team highlighted a few key challenges: 1. Temperature Control = heating is required for maximum oxidation, however too high temperatures can lead to safety concerns. This therefore requires significant temperature control and the relevant safety interlocks. 2. Addition Rate & Sequence = like many chemical processes, the addition rate is key in controlling product properties and any exotherms arising from the addition of acids and oxidising agents. 3. Oxidiser Quenching = strong oxidising agents require quenching post reaction to ensure safe waste streams at the end of the process. Controlling this process to ensure limited temperature variation is critical for safe operation.
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William Blythe is a speciality chemicals manufacturer based in Accrington, UK. The company is one of the leading manufacturers of graphene oxide globally, and a world leader in the development of inorganic chemicals since its formation in 1854. From its origins of creating dyestuffs for the textile industry in the North West, it has evolved to become a leading manufacturer of tin, copper and iodine derivatives supplied into applications such as gas purification absorbents, flame-retardant synergists for plastics and iodinecontaining food additives. Since 2012 the company has invested significantly in developing advanced materials such as graphene oxide and doped-metal oxides, expanding the product portfolio into new chemistries and applications. williamblythe.com
| CHEMICAL INDUSTRY JOURNAL |
| innovation |
Metal-eating plant method wins acclaim for ‘eco catalyst’ farmer French scientist Claude Grison has won a top European Inventor Award for her ‘green’ method of decontaminating polluted soils with metal-eating plants. The award from the European Patent Office recognises the work of the University professor and research director at the French National Centre for Scientific Research (CNRS) to extract metal elements from the soil and use them as “ecocatalysts” to make new molecules. Grison’s method helps decontaminate soil and provides a new source of catalysts, which could be used to produce biodegradable plastics, antimitotics (used in cancer treatment), capped DNA and RNA, cosmetics and key intermediates for fine chemistry.
FROM BOTANY TO CHEMISTRY Grison’s invention was inspired by a question from her students as to whether metal-accumulating plants could be used to remediate old mining sites. She realised that if she could find a way to harvest the metal contained in the plants, it would open up a new source of materials such as zinc and nickel, which are used to make catalysts for the chemical industry. Few in the scientific community believed it was possible, but Grison was undeterred. In 2011, she applied for a European patent for her method for extracting metals to produce catalysts, enabling her to commercialise her work. Grison and her team now use these ‘eco catalysts’ to produce new types of molecules for the chemical, pharmaceutical and cosmetics industries. So far, the team has synthesised 5000 such biomolecules, which they are starting to commercialise, as well as a mosquito repellent with ingredients made by eco catalysis.
Grison said that despite being a research scientist, she is motivated by the potential impact of her work. “I do not want to be a mere researcher; I want to be a citizen researcher. I want my research to be useful, so that it can be transferred towards society, that it ends up contributing, even if just a little, to solving a big problem,” she explained. Grison was honoured in the Research category of the European Inventor Awards, a hybrid event watched online by a worldwide audience. The Award is one of Europe’s most prestigious innovation prizes and is presented annually to outstanding inventors from Europe and beyond who have made an exceptional contribution to society, technological progress and economic growth. “Our Award recognises inventors that have demonstrated a new way of thinking. By marrying botany and chemistry, Claude Grison has found an original way to solve two problems simultaneously. First, her solution could help the chemical industry reduce its environmental impact. Then, she has tapped into a new source of raw materials highly valued by several industries,” explained António Campinos, President of the European Patent Office. Claude graduated with a PhD in Molecular Chemistry from the University of Lorraine, France in 1987. Between 1994 and 2003 she was a Professor of Chemistry at the University of Nancy and from 2008 to 2013 at the University of Montpellier before accepting her current position at the CNRS (also at Montpellier) in 2016. She is named inventor of European patent EP2504096B1 (granted 2019), co-owned by the CNRS and the University of Montpellier.
“I do not want to be a mere researcher; I want to be a citizen researcher. I want my research to be useful, so that it can be transferred towards society, that it ends up contributing, even if just a little, to solving a big problem,” 18
| CHEMICAL INDUSTRY JOURNAL |
| innovation |
World’s first renewable surfactant paves way for circular chemistry Cepsa Química has supplied consumer goods manufacturer Unilever with NextLab linear alkylbenzene (LAB), a new range of sustainable products which include renewable and recycled raw materials. This sets a new milestone for circular chemistry, as NextLab linear alkybenzene (LAB) is made using ‘green carbon’ derived from biomass instead of the fossil fuels the industry has employed until now to make cleaning and laundry products. Cepsa Química uses a Mass Balance approach to create NextLab. Through Mass Balance, traditional black carbon sources are blended and co-processed with those from plant-based sources, known as green carbon. Afterwards, they are tracked throughout the entire production process to ensure that an appropriate volume of the green carbon content is in the final LAS surfactant. The company claims this way of manufacturing surfactants is not only the most viable, short-term alternative to purely fossil-carbon derived products, but also constitutes a big stepping stone in the shift from petrochemical to renewable feedstocks. Unilever is the worlds’ first user of NextLab linear alkylbenzene (LAB), which incorporates biomass of certified origin, resulting in an LAB surfactant identical in properties and performance to traditional surfactants. The company will use NextLab to make Linear Alkylbenzene Sulfonate (LAS), the world’s largest-volume synthetic surfactant and its key raw material for brands such as Persil, Cif and Sunlight.
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Surfactants are crucial in the making of cleaning products. However, all LAS surfactant is made nowadays from black carbon and fossil fuels. Using a LAB made from renewable biomass to produce LAS is not only a more sustainable way to produce this raw material but also aims to help lower the carbon footprint of the final products.
ROUTE TO A CIRCULAR CHEMISTRY As of today, 85% of the overall carbon demand in chemical and derived materials sector is still met using fossil fuels. According to Cepsa Química, by offering renewable and recycled alternatives, it has set a new route to a circular chemistry industry, both in its own production process and in that of its buyers. Unilever’s Home Care business announced last year that it will source 100% of the carbon derived from black sources in its cleaning and laundry formulations with renewable or recycled carbon – a strategy illustrated in its Carbon Rainbow model. With the chemicals used in Unilever’s cleaning and laundry products making up the greatest proportion of their carbon footprint (46%) across their lifecycle, these new chemicals made with renewable feedstocks will help the company reduce its carbon footprint. A spokesperson added that including NextLab within formulations will result in no change to product performance.
| CHEMICAL INDUSTRY JOURNAL |
| icheme |
Hazards 32
18–20 October 2022, Harrogate, UK The Institution of Chemical Engineers’ (IChemE) annual Hazards conference takes place in Harrogate, UK on 18–20 October, bringing the major hazards community together in-person for the first time in over three years. Hazards 32 will help to advance the understanding of and application of managing major hazards and provide valuable networking opportunities over the three-day conference. It is an industry-focused event aimed at anyone who is active in process safety and hazard management for chemical process facilities or other facilities dealing with hazardous materials. It will benefit practitioners working at all levels and in all industry sectors.
WHAT TO EXPECT FROM HAZARDS 32 There will be over 80 technical presentations sharing examples of good practice, new approaches and valuable lessons learned in process safety that attendees can transfer to their own operations. Industry practitioners, researchers and regulators have all contributed, and there will be plenty of practical insights from operating companies. Presentations will cover a wide range of topics in the functional areas that are key to managing and reducing process safety risk effectively, including engineering and design, systems and procedures, knowledge and competence, human factors, assurance, safety culture, and environmental protection. They will also explore the emerging challenges and major hazard implications of new technologies and applications. The programme also includes a panel discussion where attendees can share their thoughts on meeting the major process safety challenges in industry, and a workshop on bowties delivered by Gold Sponsor, Wolters Kluwer.
SPEAKER LINE-UP The programme includes contributions from key international players in the process industries including Atkins, DEKRA, INEOS, Sellafield Ltd, Shell, the Health and Safety Executive, Wood and many, many more. The technical presentations will be complemented by an impressive line-up of plenary speakers. Dame Judith Hackitt will speak on the challenges of learning lessons in the industry and the importance of ethics in engineering during a lecture created to honour the memory of process safety pioneer, Trevor Kletz. Hackitt is an IChemE Fellow with more than 40 years’ experience in the chemicals industry and hazard management. She is Chair of Enginuity, the UK skills body for engineering and manufacturing. She also works as an adviser to the UK Government, chairing its Industry Safety Steering Group holding industry to account to deliver the culture change needed, and its Transition Board which is overseeing the creation of the new Building Safety Regulator. Joining Hackitt are various leaders within the major hazards industry. Jane Lassey, Director of the Health and Safety Executive’s Chemicals, Explosives and Microbiological Hazards Division, and Michelle Roberson, General Manager, Process Safety at Shell, US will explore the emerging challenges in hazard management; Lassey from a regulatory perspective, and Roberson from the viewpoint of the operator making the energy transition. The Tank Storage Association’s Executive Director, Peter Davidson, will present on the role of leadership in managing major hazards. Jasper Clark, Risk Engineering Hub Leader at
Marsh Energy & Power, will share insights from an insurance industry perspective on turning good practice into common practice. And the Chemical Industry Association’s Chief Executive, Steve Elliott, will present on the importance of cross-sector learning.
TRADE EXHIBITION AND INDUSTRY SUPPORT A trade exhibition will run alongside the conference, showcasing products and services to support the major hazards community. Several leading companies in the industry have already pledged their support by sponsoring Hazards 32 including Wolters Kluwer, BakerRisk, ESR Technology, MES and ABS Group. There are more packages available to suit all budgets, and companies interested in sponsoring or exhibiting at Hazards 32 can learn about the opportunities that are available on the event website.
NETWORKING OPPORTUNITIES Hazards was last held in-person in May 2019. IChemE’s virtual conferences have continued to facilitate knowledgetransfer and learning since, but they couldn’t replicate the valuable networking opportunities available at an in-person event. Social time including a free welcome drinks reception and an informal evening event will encourage attendees to rebuild networks and make new contacts. And facilitated discussion time during the programme will encourage attendees to share experiences and learn from each other, whilst helping to identify the common issues facing industry practitioners. To learn more about Hazards 32 and to register to attend on 18–20 October, visit www.icheme.org/hazards32
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Hazards32 Join the major hazards community at Hazards 32 to review good practice, current thinking and lessons learned in process safety and hazard management, and explore some of the challenges and opportunities in process safety today. Hazards 32 is an industry-focused event ideal for anyone who is active in process safety and risk management for chemical process facilities or other facilities dealing with hazardous materials.
It is an exciting chance to reconnect with fellow professionals, rebuild networks and share insight and experiences in person once again.
Key features Q Q Q Q Q Q
Technical presentations from industry practitioners, regulators and researchers Facilitated discussion time and Q&A Inspirational plenary speakers Trevor Kletz Hazards Lecture Exhibition hall Social and networking opportunities
Speakers
Dame Judith Hackitt
Trevor Kletz Hazards Lecture
Peter Davidson, Tank Storage Association
Plenary Speaker Leadership
Jasper Clark, Marsh Energy & Power
Jane Lassey, Health and Safety Executive
Plenary Speaker Embedding Good Practice
Plenary Speaker New Technologies
Michelle Roberson, Shell Group
Steve Elliott, Chemical Industries Association
Plenary Speaker Energy Transition
Find out more and register:
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Plenary Speaker Cross-Sector Learning
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| CHEMICAL INDUSTRY JOURNAL |
| cba |
Our big challenge: recruiting future talent in the chemical industry Across the globe, the chemical industry and the supply chain is struggling with critical supply and demand imbalances. This applies not only to raw materials and commodities, but also to talent. Tim Doggett, CEO of the Chemical Business Association (CBA), looks at how the chemical industry can attract diverse future talent and help bridge the existing skills gap. The chemical industry powers the modern world as we know it, with over 95% of industry using chemicals. It is the second largest manufacturing industry in the UK, directly employs more than 94,000 people - an estimated 205,000 indirectly – and has a turnover in excess of £73 billion. It is a significant contributor to the country’s economy and will remain pivotal to the economic prosperity of the UK for the foreseeable future. A large and complex supply chain is in place to maintain and support the chemical industry, requiring a wide range of skills, job functions and ancillary industries to work effectively. It is imperative therefore that as the chemical industry develops its strategy for the future, it understands all aspects of the supply chain and works to develop and maintain it.
SPARKING AN INTEREST Whilst the chemical supply chain industry has been impacted by a combination of extraordinary forces that have challenged the entire global supply chain in unprecedented ways over the last few years, it continues to be plagued by another threat – a chronic shortage of talent. In general, there appears to be three reasons for this: the impending retirement of experienced employees; a perceived skills shortage among the generation that will replace retirees; and the general unpopularity of the industry as an employer of choice. Additionally, the general public has a poor perception of both the chemical and logistics industries. To attract more diverse talent, the negative view of careers in both the chemical and logistics industries must change. This can only be achieved if companies start combating stereotypes by advocating for their organisations, by informing the public of the industry’s overarching value, and by showcasing the range of inclusive opportunities available in the wider chemical industry. One programme launched specifically to shift perceptions and encourage people to engage with the logistics sector for example, is Generation Logistics, of which CBA is an unofficial partner. The association itself has launched various initiatives aimed at getting the younger generation interested and involved in the chemical industry, including setting up a Future Council, which promotes the chemical supply chain, encourages future industry talent, and promotes STEM education. In 2019 the CBA also introduced the Young Person’s Award with the aim of recognising excellence within the chemical supply chain. Additionally, the association and its members have supported ‘Chemistry with Cabbage’, a programme set up by Lorelly Wilson MBE with the aim of engaging primary school students in practical chemistry, for many years.
Tim Doggett Chief Executive of the Chemical Business Association
“To attract more diverse talent, the negative view of careers in both the chemical and logistics industries must change” BRIDGING THE GAP The chemical industry has always been resilient and despite ongoing disruptions, it remains a vital sector for the UK economy. To ensure it attracts the diverse and inclusive talent pool required to maintain this position, it must be showcased as an attractive and exciting industry in which to build a career. As such, there is a vital need to act now to attract future talent with the aim of providing the industry with a steady stream of skilled workers. However, recruitment is just one step in the process. Employee mentoring, training and development are crucial elements to bridging the skills gap and companies in the chemical industry must commit to prioritising skills development, either by offering vocational training and skills programmes or by supporting opportunities for continuous learning. Additionally, incoming talent must be educated about the importance of the industry to the economy and society at large. By sparking their interest and creating awareness of the vital role chemicals play, industry will be able to attract a new generation of workers who are keen to see the chemical industry thrive.
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| CHEMICAL INDUSTRY JOURNAL |
| novaflex |
Novaflex – Process Flow The Novaflex Group is a market leader through excellence in product innovation and a commitment to continuous advancement in hose and connector solutions.
COMPOSITE HOSE
EXTRUDED THERMOPLASTIC DUCTING Novaflex offer a wide range of ducting products for air and dust control, light material handling and wet or dry fume control, and many other applications. Novaflex ducting is lightweight, flexible and economical.
COUPLINGS Novaflex composite hoses are manufactured to meet British and European standards BS5842, BS3492, and BS EN 13765. Novaflex composite hoses and assemblies hold Lloyd’s Register Certified Type Approval for BS EN 13765:2018. Novaflex have manufactured composite hoses in the UK since 2008 and supply thermoplastic composite hoses in diameters ranging from 1” to 12” in lengths of up to 40 metres. Hoses are made to a wide range of specifications for a wide range of chemical, application, and customer requirements.
RUBBER HOSES
Drawing on decades of real world application experience, the NovaFlex® Hi-Flow™ Dry-Release™ ‘HDC®’ Couplings optimise every area of function and design to deliver a truly innovative and reliable safety product. Safety Breakaway Couplings by Novaflex® provide the highest standard of safety technology to protect personnel, critical assets and the environment. Fittings are also available in a range of threaded and flanged designs specifically designed to work with our range of Novaflex hoses. www.novaflex.com
The Novaflex rubber hose range includes material handling, chemical, food grade, and mining hoses, as well as a range of expansion joints and connectors. Novaflex rubber hoses are available in a wide range of diameters in EPDM, UHMWP, Teflon, Nitrile, and Viton, for resistance to chemicals, abrasion, heat and corrosive conditions. Hoses are manufactured in North America and comply with FDA, 3A, USDA, and REACH standards.
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| CHEMICAL INDUSTRY JOURNAL |
| oem |
AUTOMATION COMPONENTS FOR THE CHEMICAL INDUSTRY Chemical processing and production are part of a huge billion-pound industry. The importance of chemistry means there is no room for inaccuracies.
WAFER BALL VALVES Wafer ball valves provide a reliable seal, making them fit for challenging applications. High quality, Italian-made stainless-steel wafer ball valves are available in various sizes and are ATEX-certified.
Automated equipment assists professionals in the chemical industry to undertake R&D, product management, chemical engineering and other critical roles in the chemical industry.
VALPES ELECTRIC ACTUATORS Valpes are specialised in providing ATEX approved electric actuators. See our section on ATEX rated products to find out more.
This article looks at products OEM Automatic supply suitable for use in chemical production and processing. Some specialist engineers might find this article of interest.
FLOW SWITCHES
WHAT IS CHEMICAL PROCESSING AND PRODUCTION?
The Honsberg FF Series flow switch is a simple unit which indicates when a specific flow rate has been achieved and can be used with aggressive media such as corrosive and abrasive flows.
The chemical process consists of materials being created and processed into finished products. This can include purification, separation and creating chemical reactions between materials. Often, active ingredients are used within chemicals to create finished products – and this is where specialist equipment is required. Components should be robust, long-lasting and made from the correct materials. Chemical production describes the manufacturing of chemicals to be used in industries such as pharmaceuticals, agriculture, and a wide array of manufacturing applications.
This flow switch is suitable for the chemical industry as it is available in stainless steel and has a pressure range from 16 bar up to 200 bar.
CHEMICAL FLOAT SWITCHES Technoplastic’s chemical float switch is designed specifically for the chemical environment. Unlike traditional floats that float on the water’s surface, the Taurus level switch remains underwater. Suitable for medical and scientific facilities, hydrocarbons and more.
PROCESSES WITHIN THE CHEMICAL INDUSTRY
ATEX RATED
Cleaning and sterilisation of products and product handling Movement of media Temperature measurement Level measurement and detection Transformation processes of plasticisers, polymers, additives and active principles Transfer within production processes (supply, pressure boosting, discharge) Metering and filling
ATEX rated equipment ensures that components are fit for use in potentially explosive atmospheres. Many operations in chemical production require this rating. ATEX RATED SAFETY SWITCHES IDEM’s explosion-proof safety switch range is developed to satisfy the latest IECEx and ATEX standards, creating explosion-proof switching. They combine explosion proof protection and satisfy high functional safety requirements all in one device. ATEX RATED ELECTRIC ACTUATORS These are suitable for any potentially explosive or hazardous environments. An electric actuator allows a valve to be adjusted remotely or large valves to be operated rapidly and play a major part in automating process control.
VALVE PACKAGE SUITABLE FOR THE CHEMICAL INDUSTRY Designed specifically for the chemical industry, we can provide a package of actuated valves. NEW OMAL VIP EVO CO-AX VALVE UP TO PN40 The Omal VIP EVO Co-Ax valve is a macro pneumatic valve with benefits such as:
Valpes’ existing range of ATEX electric actuators has new certifications, achievable for new markets with EACEx (Russia) and IECEx (international) certification, also compliant with the latest requirements of the ATEX directive (2014/34/EU).
Pneumatic actuator integrated into the valve Several seals available 70% less air consumption in comparison to an actuated valve with SR pneumatic actuator ATEX certification The VIP EVO Co-Ax valve will be available soon…
PRODUCTS THAT CAN HANDLE AGGRESSIVE MEDIA STAINLESS STEEL COMPONENTS The benefit of stainless steel is that it can withstand highly corrosive substances and has excellent mechanical characteristics. This helps achieve quality standards and is often seen in the chemical environment.
PRO-CHEMIE BALL VALVES The Pro-Chemie ball valve is carefully designed for the chemical sector. It’s mainly used in the transformation processes of plasticisers, polymers, additives, and active principles.
IP69K To handle aggressive media, IP69K components are recommended. They can withstand harsh environments such as chemical washdown or the presence of aggressive oils, lubricants and dust.
The seals are completely independent of the shaft rotation to protect it from radial wear, delivering up to 60,000 cycles with no fugitive emissions.
Most of the components mentioned in this article have an IP69K rating.
Standard features include SIL3 / ATEX. Pro-Chemie ball valves are available as manual or automated using Omal’s scotch yoke actuators.
The above are just some of the components suitable for chemical applications. Read our full article for more: www.oem.co.uk/ resources/blog/chemical-processing-and-production.
PNEUMATIC SCOTCH YOKE ACTUATORS A scotch yoke actuator converts linear force into torque to motorise quarter-turn valves.
Email pressureandflow@oem.co.uk with your specific requirements, and we can find a solution for you.
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| CHEMICAL INDUSTRY JOURNAL |
| vega |
VEGA Radar Level sensor: Simplicity, Safety and Security SIL approval and IEC Cyber security standard for THE 6X® As well as offering one of the simplest methods for model selection and ordering, whether for liquids or for bulk solids the VEGAPULS 6X level radar provides 1mm accuracy performance and measuring ranges up to 120m. It also features extended temperature and pressure capabilities, along with a dedicated second generation 80 GHz radar chip that affords greater diagnostic functions and optimal signal processing. If we had to make a list of the most important innovations in VEGAPULS 6X, the radar chip would be right at the top. At the sensor’s heart, it is the pulsating technology that empowers it to fulfil the highest expectations in terms of precision and reliability. And this is mainly due to its ability to self-monitor during operation, which makes it possible to seamlessly and continually diagnose the sensor performance and its accuracy as a system. This technology means it operates in virtually any level application you can think of - from measuring very light hydrocarbons in a storage sphere, high security floatingroof tank levels, to large rocks in a primary crusher. But some critical applications demand more than just ‘a reliable measurement’, they demand a high degree of safety too. In light of this, THE 6X has now expanded its capabilities to SIL 2/3 conformance based on its highly comprehensive diagnostic coverage, while also adding in a new level of IT security, too. For SIL applications it has new test options to make verification easier, with the SIL-by-design architecture enabling it to utilise its full internal diagnostics for function testing. And, depending on the method chosen, it can attain a diagnostic coverage of up to 99.1% - a market-leading figure for a non-contact radar level sensor. In view of the increasing digitalisation in industry, another extremely important factor is ensuring effective protection against
cyber-attacks. That’s why it also offers an I.T. security standard IEC 62443-4-2, which means on your critical safety systems, you can combine both the highest cyberprotection currently established for the process industry with SIL 2/3. As one of the first field devices to do so, you can choose THE 6X when you need safety and security in your level measurement application. If you want to know more, arrange a training session on this product, or get more information on these latest features contact info.uk@vega.com
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WE DON’T DO A HUNDRED THINGS. WE DO ONE THING RIGHT! THE 6X®. OUT NOW! We have known this for over 60 years. That’s why this new radar level sensor is not available in 100 different versions, just one perfect one. The VEGAPULS 6X is highly versatile, absolutely reliable and works in any process and environment. The only thing it doesn’t do is stress.
VEGA. HOME OF VALUES. www.vega.com/radar
| CHEMICAL INDUSTRY JOURNAL |
| news |
Nanochannels light the way to new medicine
The chip is secured in a specially adapted optical dark-field microscope and illuminated with visible light. (Credit: Envue Technologies | Maja Saaranen)
The development of new drugs and vaccines requires detailed knowledge about nature’s smallest biological building blocks – biomolecules. Swedish researchers have devised a new microscopy technique that allows proteins, DNA and other tiny biological particles to be studied in their natural state in a unique way. A great deal of time and money is required when developing medicines and vaccines. It is therefore crucial to be able to streamline the work by studying how, for example, individual proteins behave and interact with one another. This new microscopy method from Chalmers University of Technology allows the most promising candidates to be found at an earlier stage. The technique also has the potential for use in conducting research into the way cells communicate with one another by secreting molecules and other biological nanoparticles. These processes play an important role in our immune response, for example.
REVEALING ITS SILHOUETTE Biomolecules are both small and elusive but vital, since they are the building blocks of every living thing. Researchers currently need to either mark them with a fluorescent label or attach them to a surface to get them to reveal their secrets using optical microscopy. “With current methods you can never quite be sure that the labelling or the surface to which the molecule is attached does not affect the molecule’s properties. With the aid of our technology, which does not require anything like that, it shows its completely natural silhouette, or optical signature, which means that we can analyse the molecule just as it is,” says research leader Prof. Christoph Langhammer, of the Department of Physics at Chalmers. He has developed the new method together with physics and biology researchers at Chalmers and the University of Gothenburg. The method is based on the molecules or particles under study being flushed through a chip containing tiny nano-sized tubes, known as nanochannels. A test fluid is
added to the chip which is illuminated with visible light. The interaction between the light, the molecule and the small fluid-filled channels makes the molecule inside show up as a dark shadow and it can be seen on the screen connected to the microscope. By studying it, researchers can not only see but also determine the mass and size of the biomolecule and obtain indirect information about its shape – something that was not previously possible with a single technique.
ACCLAIMED INNOVATION The new technique, nanofluidic scattering microscopy, was recently presented in the scientific journal Nature Methods, and has also received acclaim from the Royal Swedish Academy of Engineering Sciences. The innovation is now being championed through start-up company Envue Technologies. “Our method makes the work more efficient, for example when you need to study the contents of a sample, but don’t know in advance what it contains and thus what needs to be marked,” says researcher Barbora Špačková, who during her time at Chalmers derived the theoretical basis for the new technique and then also conducted the first experimental study with the technology. The researchers are now continuing to optimise the design of the nanochannels to find even smaller molecules and particles that are not yet visible today. “The aim is to further hone our technique so that it can help to increase our basic understanding of how life works, and contribute to making the development of the next generation medicines more efficient,” says Langhammer.
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| CHEMICAL INDUSTRY JOURNAL |
Powder Processing Equipment and Systems
Automatic Reactor Dosing
Applications
Your benefits
• • • • •
• Safe product handling with minimum emissions • Reliable vapour barriers • Complete insertion of products and quick wetting of the particles • High safety due to inert gas overlay
Safe docking of vessels Process controlled feeding of reactors Batch processes Feeding below the liquid level Pressurised conveying into a reactor
For more information on Gericke’s systems, components and industry leading experience, please visit www.gerickegroup.com Gericke Ltd, Victoria House, Cavendish Street, Ashton-under-Lyne, Oldham OL6 7DJ
ProductTraq
Substance Volume Tracking (SVT) in the chemical supply chain
PSMmonitor
Action Tracking Accident & Incident Management of change
0161 344 1140
Cloud-based Subscription-based Configurable
ReachSuite
Consortia collaboration REACH K-REACH UK-REACH
Find out more:
www.baytouch.com
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| CHEMICAL INDUSTRY JOURNAL |
| big interview |
Seamus White, Bachem Business Development Manager
Oligonucleotides: the journey so far For oligonucleotide api manufacturers, putting in place capacity and sustainability solutions will be essential to meet increased demand. The molecules will be needed in ever greater quantities to fulfil rising needs as new uses are found in research, diagnosis and drug development. Seamus White, Bachem business development manager, tells Chemical Industry Journal how oligonucleotide therapeutics could simplify the work of pharma and biotech companies.
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| CHEMICAL INDUSTRY JOURNAL |
| big interview |
WHAT MOTIVATED BACHEM TO GET INVOLVED IN THE FIELD OF OLIGONUCLEOTIDES IN 2008? Oligonucleotide-based medicines are increasingly being recognised for their role in treating rare diseases and their potential therapeutic benefits for chronic diseases. It’s likely that as these molecules get the attention they deserve, demand will continue to grow. At Bachem, we noticed that needs around capacity, cost-effectiveness and sustainability aren’t yet being met in this field. We saw this as an opportunity to support the development of API by taking advantage of existing expertise and equipment, and to expand our customer base. We believe our work will help our customers make significant, innovative strides in this area and can bring huge improvements for larger numbers of patients by improving supply.
WHAT HAS BACHEM BEEN ABLE TO ACHIEVE SO FAR? Our first actions were to buy and install synthesis automates and to dedicate resources to designing and creating a unique cleavage and deprotection system, which is used for complex siRNAs synthesis in multi-hundred gram quantities. This enabled us to release the first GMP batch for use in clinical investigations in 2019. The qualification of the pilot plant, which will be used for the downstream processing of oligonucleotides, was finalised in 2021, and will enable greater efficiency in processing materials in quantities that fall within the single kilogram range under GMP conditions. Another exciting development has been the recent installation of the first of our large-scale equipment trains. Collaboration with other pharma and biotech companies has already begun for this line, which is designed for oligonucleotides and the process of synthesising multi-kilogram batches.
WHAT ARE THE KEY INNOVATIONS IN YOUR MANUFACTURING PROCESS? Over the last few decades, we’ve been working to perfect our specialised engineering methods for large-scale solid-phase synthesis, chromatographic purification and lyophilization. Some solutions can be adapted for use with peptide APIs and also for oligonucleotides. A key example of this is crude material purification using MCSGP technology in continuous chromatography mode. We believe that this technology has the potential to reduce both costs and waste. More broadly, we are also utilising the knowledge and experience of our scientists in solid phase synthesis
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and protecting group chemistry to develop multi-faceted solutions to boost the scalability and sustainability of the oligonucleotide synthesis process.
WHAT ARE YOUR THOUGHTS ON THE FUTURE MARKET? The potential for oligonucleotide medicines in curing rare diseases is beginning to be realised, as shown by the approval of 14 medicines by the FDA and EMA. This progress is accelerating, with roughly 200 clinical and 600 pre-clinical trials currently ongoing for oligo-based products. We want to support our pharmaceutical and biotech partners in developing and manufacturing their oligo-based therapeutics, so that they can keep pace with this growing market and make a real difference to patients’ lives.
HOW IS BACHEM RESPONDING TO MARKET DEMAND? In short, we have to ensure continued investment in our peptide and oligonucleotide manufacturing capacities and capabilities on a global level. This is already beginning with our plans to invest in $500 million worth of new equipment and production facilities in the coming years, and with construction of a new TIDES manufacturing facility at our Bubendorf site. This facility will include further equipment trains to enable the commercial-scale production of oligonucleotide APIs.
WHAT ARE YOUR PREDICTIONS FOR OLIGONUCLEOTIDE THERAPEUTICS? The need for progress in regards to the scalability and sustainability of oligo manufacturing will become increasingly clear. Bachem has recently begun an internal innovation programme to find these solutions. We are beginning to observe developments in medicinal chemistry and oligonucleotide conjugation, and the increasing complexity of molecules, with a range of conjugation moieties and backbone modifications. This will allow new pharmaceutical targets outside of the liver to be addressed with oligonucleotide medicines.
WHAT DOES THE FUTURE HOLD FOR YOUR OLIGONUCLEOTIDE TREATMENTS? We believe our therapeutics are well paced thanks to our experience in the conjugation chemistries of peptides, lipids, PEG and many more, as well as our capacity for expert analysis. We hope that our innovations will be transformational for our clients and partners, and, of course, for patients.
| CHEMICAL INDUSTRY JOURNAL |
| ras |
What is the Value of the Environment? Valuation of Environmental Harm for COMAH Cost Benefit Analysis COMAH environmental risk assessment is typically performed in line with the Chemical and Downstream Oil Industries Forum (CDOIF) Guideline on Environmental Risk Tolerability for COMAH Establishments (V2.0). This involves prediction of whether there is the potential for Major Accidents To The Environment (MATTEs), rated A through D with increasing consequence. The results of such assessments often involve conclusions that the risk to certain environmental receptors is tolerable if As Low As Reasonably Practicable (ALARP). Therefore, subsequent demonstration that the risk is indeed ALARP is required. ALARP decisions and conclusions can often be based on engineering judgement and operational feasibility. However, where this is not possible, cost benefit analysis (CBA) can, in theory, be useful. One element of CBA is the cost of environmental damage (or value of preventing it), which requires assigning monetary values to the environment for use within CBA calculations. If the cost of implementing a proposed risk reduction measure is grossly disproportionate to the justified spend to reduce risk, then rejection of the measure can be justified. This is analogous to the approach taken for safety risk to people, for which there is a longestablished monetary value for the prevention of loss of a single human life. However, considering the environment, there is no such benchmark. If CBA is to be used effectively for environmental risk, then it would make sense to have analogous benchmark values in place. Current guidance suggests that the value(s) to use should be estimated on a case-by-case basis and consider a series of cost influencing factors. For example, clean-up costs, restoration and ongoing monitoring, fines and civil liability claims such as loss of fisheries, impact on tourism or loss of water abstraction. It is also suggested that business related costs such as production downtime, asset damage and raised insurance premiums should not be included. Therefore, it is understandable that consistency across the industry is difficult to achieve, even for very similar sites and risks, yet different operators. Taking fines as an example, estimating these for MATTEs that you might cause could look to previous incidents of a similar magnitude for an indication. Whilst there is a multitude of legal guidance and protocol to be followed when fines are issued, there is still significant scope for variation. The nature of an offence feeds into the magnitude of a fine and involves
both culpability and harm. Culpability is split according to whether the offence is judged to have been deliberate, reckless, negligent or with low to no culpability. This cannot be reliably predicted before an accident occurs. Another factor is the size and turnover of the offending organisation. There is vast scope for inconsistency on how incident data is used, depending on which and how many incidents are reviewed and on any assumptions made. Identifying and then accounting for all cost influencing factors is a vast challenge. Without set figures, even as benchmarks or guidelines, there is the risk of immense over or under-estimation, prompting questions about the value of performing such calculations. One of the most important aspects of a Cost Benefit Analysis is determining whether one should be conducted in the first place. Often, CBAs are misused, potentially resulting in disastrous outcomes, especially if the incorrect values for the environment are used. Most of the time it should be evident whether a measure should be implemented. There are cases however where understanding the economics of suggested measures can be helpful, for example when comparing multiple options, and for this a reliable value of environmental harm is required. Going forward, efforts are underway to develop a set of benchmark values for different MATTE levels to different types of environmental receptors and to produce an industry guidance document. This should help to improve consistency across different companies, sites and also geographically and ensure a more level playing field for everyone. RAS Ltd has been commissioned by the Energy Institute on a project to do this, with ambitions to publish industry guidance. Part of this involves a detailed interrogation of incident data and costs, with a view to revealing patterns that can feed into any set of benchmark values. Rob Ritchie and Carolyn Nicholls enquiries@ras.ltd.uk
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RAS RISK & HAZARD MANAGEMENT
Understanding and facilitating the effective management of risk is our core business. Our expertise covers the full range of risk assessment and management services across:
Safety Risk
Business Risk
Environment Risk
Only when the risk facing an organisation is well understood can it be effectively managed.
Key to the successful identification, assessment and management of risk is engagement with the right
people, using the right processes at the right time. We believe we are different to many of our competitors and our approach is distinctive, we don’t always walk the well-trodden path but look at each client’s particular risk context and develop a tailored solution, working in partnership with our client. We work across all aspects of risk, from Quantitative Risk Assessments and Predictive &
Consequence modelling, through to the ‘softer’ risks which may affect an organisation’s reputation.
+44 (0) 1244 674 612 • enquiries@ras.ltd.uk • www.ras.ltd.uk
| CHEMICAL INDUSTRY JOURNAL |
| industry 4.0 |
AI for plant monitoring: platform or purpose-built? 34
| CHEMICAL INDUSTRY JOURNAL |
| industry 4.0 |
Andrew Normand, UptimeAI partnership lead at Encora Energy, discusses which approach could be the right fit for your business. Industry 4.0 is the watchword for the fourth industrial revolution that’s taking place right now. Nearly every global chemical manufacturer is investing in disruptive technology with advanced analytics and artificial intelligence (AI). When applied to monitoring plant equipment these can give significant advantages in plant uptime, increased efficiency and cost reduction. However, one of the critical choices that companies face is deciding between building apps on AI-based platforms or purpose-built AI software for plant monitoring. While both have their place in the world of digital transformation, which approach is the right one for your organisation? There are significant differences between both solutions, and choosing an approach requires careful consideration of their pros and cons. AI platforms help software, data science and IT engineers bring together disparate technologies to build an analytics application. To address this, AI platforms offer an integrated environment with pre-built data connectors, transformations, machine learning models, user interface (UI) development, and DevOps tools. Essentially, platforms are tools to build your analytics. On the other hand, purpose-built plant monitoring solutions are developed for plant engineers to increase the availability and efficiency of plant operations. They offer pre-built connectors, data transformations, models, dashboards and deployment options that are designed specifically for the challenges in plant monitoring.
CORE FUNCTIONALITY Platforms offer software and data science functionality but require the user’s knowledge of workflows and plant operations. While some of the platforms provide prebuilt apps for predictive maintenance, they can lack an understanding of equipment and processes and are often too data science-driven. In contrast, AI-based purpose-built solutions bring the software, data science, domain knowledge and workflows into a single application. However, these solutions are limited to algorithms and technology that’s specific to solving plant issues. For example, a purpose-built solution won’t have a connector for stock market data, whereas a platform is likely to have this feature.
COST AND RETURN ON INVESTMENT Building a plant monitoring solution on an AI platform can be a costly endeavour that can run into tens of millions of pounds on top of the platform costs. Users have to bear the cost of developing a solution. As a result, the return on investment (ROI) is often lower and takes longer with AI platforms. Often users start out with a pilot and then get stuck there. AI-based purpose-built solutions are typically much cheaper to get started, typically a few hundred thousand pounds per year. A vendor offering a purpose-built solution distributes the cost of building the solution over multiple customers; hence the price of the software to the end customer is much lower. As a result, ROI is generally much faster and higher – typically in six months or less. However, significant customisation on purpose-built solutions can be costly and may not even be possible.
SUMMARY AI platforms and purpose-built AI solutions for plant monitoring both have merits and limitations. With AI
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Andrew Normand UptimeAI partnership lead for Encora Energy Andrew Normand is UptimeAI partnership lead for Encora Energy. With more than 15 years’ professional experience and an extensive global background in technical/management consulting and operations-based engineering, Andrew is currently driving forward Encora Energy’s roll-out of UptimeAI’s pioneering technology in the UK and Europe. Andrew and the Encora Energy team offer in-depth knowledge of the European process industries – particularly the energy, oil, gas, chemicals and power generation sectors – as well as the regulatory environment in the UK and Europe.
platforms, it’s a do-it-yourself job, whereas purpose-built solutions offer a ready-to-use solution. Unlike more straightforward use cases such as sales or demand forecasting, plant monitoring applications are highly complex due to the integration of IT, OT, operational workflows, domain knowledge, changing process conditions and data science. As an analogy, developing your own plant monitoring application on an AI platform is like building your car from scratch. Is it easy? Are the results guaranteed? Do you have the budget, experience and skillset? Perhaps not. But if you get it right, you may be able to build your own Ferrari! Despite the odds, AI platforms offer the promise of building something unique and custom. Organisations prepared to justify such investment to gain a competitive edge should consider this approach. For the rest, dedicated AI-based plant monitoring solutions offer the quickest and highest ROI. However, one needs to carefully evaluate the true AI capabilities as these solutions are pre-built. Alternatively, organisations may choose to go with a hybrid approach. A purpose-built AI solution could be chosen for plant monitoring, and custom applications on AI platforms for less complicated uses in sales, marketing, HR and finance. For more information, visit uptimeai.com.
| CHEMICAL INDUSTRY JOURNAL |
| health and safety |
Can obsolete parts contribute to workers’ safety? The benefits of using obsolete spare parts rather than replace a whole machine are well documented when it comes to effectiveness and compliance. Worker safety, however, is often overlooked, with part failure leading to unsafe work environments. Neil Ballinger, head of EMEA at EU Automation, explains how correct obsolescence management can keep production at optimal levels by preventing unsafe work environments and further chemical plant damage. A 2021 Senseye report found that among the Fortune 500 Global list, oil and gas companies lose $46 billion a year to unplanned downtime. Downtime caused by machine failure can be damning for smaller chemical processing companies, with expenses coming from repair costs, lost production, quality assurance (QA) issues and contractual compensation. New parts, although usually cheaper upfront than obsolete parts, can lead to further lost revenue if surrounding legacy equipment requires updating to function.
COMPLIANCE
Part failure is especially important in the chemical processing industry, where there may be dangerous substances in high-pressure environments. For example, the recent 2,500-gallon sulfuric acid spilled at a Shell cracker plant in Pennsylvania, USA, was caused by a single flange valve failure.
Obsolete parts are those that have been discontinued by the manufacturer and can include second-hand parts or refurbished used parts. Such parts can help reduce downtime in chemical processing as they are identical to the failed part and are already compliant to regulations.
Not only can a failure lead to possible damage to other machinery but is also a hazard to workers and the maintenance team needing to conduct repairs. The need for specific clean-up operations and PPE for repairs can only further the costs and prolong downtime. It has long been known that incidents in the chemical processing industry might be caused by single parts. For example, piping causes a third of failures, with a third of these leading to fire and explosion. Monitoring ageing equipment is crucial, and sourcing obsolete parts can ensure ease of replacement for equipment with high failure potential, avoiding the need for system-wide replacement and further downtime.
Due to the strict regulations surrounding the chemical processing industry, including the 2015 Control of Major Accident Hazards Regulations, the testing of equipment feeds into the cost of downtime. When legacy equipment fails and a new part is installed, the equipment will need retesting and recertification to ensure compliance. If the rest of the system needs adapting, the whole production line will need retesting as well. This is where obsolete parts can help.
The rarity of unused obsolete parts can make them especially difficult to track down unless users purchase them from a credible provider. If sourced correctly, using replacement obsolete parts can have a number of benefits. Quick delivery (leading to reduced downtime), maintenance of system compliance, and freedom from system adaptation, all make obsolete parts a cost-effective option for chemical manufacturers. Warrantied obsolete parts should reassure manufacturers that failure is unlikely, ensuring the safety of workers, which is an overlooked priority in the industry. Above all, safe environments are crucial for maintaining production, for the workers, the machines, and the reputation of your business.
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A global leader in environmental and advisory solutions
We help businesses get the most from their assets by developing people, plant, and management processes to drive sustainable improvements in safety, environmental protection and productivity.
Find out more about how we can help improve your performance safetyadvisoryeu@slrconsulting.com
www.slrconsulting.com
| CHEMICAL INDUSTRY JOURNAL |
| greener manufacturing show |
The Greener Manufacturing Show Returns to Koelnmesse, Cologne The Greener Manufacturing Show Returns to Koelnmesse, Cologne, Germany with Cutting-Edge Innovations to Accelerate your Transition Towards a More Sustainable Future on 9-10 November 2022 The must-attend event to see sustainable manufacturing solutions, The Greener Manufacturing Show Europe, colocated with Plastic Waste Free World Expo and Conference, returns to Koelnmesse, Cologne, Germany, for its second year on 9-10 November. Pioneering industry exhibitors will showcase the latest tech to help you reduce emissions and improve sustainability across your value chain. Alongside the exhibition, the conference will host 130+ renowned industry speakers. In 2022 more than 3,000 high-quality visitors and key industry brands will be attending, including Circularise, Lenzing, Siemens, Trinseo, Valmet, UN Industrial Development Organization (UNIDO), Prevent Waste Alliance, and event sponsors Mondi. Launched in 2021, the trade fair and conference attracted just under 2,000 in-person attendees, despite Covid-19 restrictions. It was apparent that companies from many sectors have begun placing sustainability at the top of their agenda. Mike Robinson, the CEO of the company that organises the event Trans-Global Events, said: “When we created the event concept, we could clearly see that there was a very urgent need for manufacturing industries to find new sustainable and environmental solutions. “The desire to develop more sustainable products is a global shift, where many are adopting new technologies and strategies to help reduce the negative effects of industry on the environment.” The Greener Manufacturing Show is co-located with Plastic Waste Free World Conference & Expo and purchasing a single conference pass gives you access to both events. “The first edition Plastic Waste Free World Conference & Expo launched in 2019 with the goal of helping manufacturing companies find new solutions to help tackle the global plastic waste crisis – whether this is through new materials, eco-design, consumer engagement strategies, or innovative end-of-life solutions. “The Greener Manufacturing Show released during the Covid-19 pandemic, and with just under 2,000 in-person attendees in 2021, it showed that companies from many different sectors are placing sustainability at the very top of their agenda,” said Robinson. The conference streams will cover different sectors and a wide range of topics, including: Sustainability In Manufacturing Retail, Consumer Goods & Packaging Fashion & Textiles Sustainable Materials Not only does the event allow businesses to attract a growing number of sustainability-conscious customers, but it also provides exhibitors with opportunities to expand into various markets. The Plastic Waste Free World Conference & Expo that took place in Atlanta in June gave Sirane Group, one of the exhibitors, the chance to expand into the US market.
Sirane Group’s NPD Lead Rachel McKenna wrote: “Atlanta has provided us with a great opportunity to share our technologies with the market. “In the USA, we have recently partnered with PrintPack; they are supplying commercial reels of EarthFilm, offering in-house printing for customers. As of August 2022, Sirane will be opening a pouch conversion facility in Grand Prairie, Dallas, Texas.” The Greener Manufacturing Show and Plastic Waste Free World will also help businesses comply with sustainability policies being developed worldwide as governments aim to reduce their environmental impact. The EU will in the near future enforce new regulations across several industries. Soon, construction products will be required to be greener and safer. Reporting and tagging information across the value chain will become essential in adhering to sustainability standards. EU member states will be obligated to pay a levy of €0.80/kg of non-recycled packaging waste. Fashion companies will need to rethink textile designs to increase the life span of garments and to make them easier to recycle. Make sure to take advantage of the numerous opportunities, solutions and innovations available at the Greener Manufacturing Show Europe co-located with Plastic Waste Free World to succeed in a fast-transitioning world focused on sustainability. For more information visit: www.greener-manufacturing.com www.plasticfree-world.com
EUROPE
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| CHEMICAL INDUSTRY JOURNAL |
| software automation |
Industrial automation makes way for information automation Collecting, analysing and extracting value from data is the next step in optimising industrial processes. But it’s still a sadly underutilised process, says Jason Chester, Director of Global Channel Programs, InfinityQS. Automation has been the driving force behind manufacturing advancement, dating back decades. Replacing physical tasks with automation has served as the bridge taking industries into the era of mass production that we know today. Businesses are always striving to rise to the forefront of new developments in technology or employ new industrial initiatives. All of this acts in service of making significant efficiency and productivity gains and ultimately increases growth and profits. Today, the vast majority of manufacturing processes are automated on some level, and only growing more so. But can the same be said for our cognitive activities and information-related processes? Collecting, analysing
and extracting value from data is surely the next step in optimising industrial processes, yet the way it is currently treated in terms of technological investment and prioritisation would suggest otherwise. As the big wins from industrial automation have already been had, it continues to deliver ever-diminishing returns. Instead, the manufacturing sector needs to turn to the valuable data that often sits unused or underutilised within their production environments. Doing so can dramatically improve the efficiency and productivity of production operations, eradicate waste and greatly improve product quality. It’s time for manufacturers to pivot and focus their attention on the data-driven side of industrial manufacturing.
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| CHEMICAL INDUSTRY JOURNAL |
| software automation |
manually. This is a tedious waste of workers’ time – time that can be better spent putting employees where they are needed the most and maximising organisational profits. What’s worse, the risk of human error with data entry is much higher than through an automated system, leading to results and analysis that might not be entirely reliable all of the time.
IMPROVING EFFICIENCY AND OPTIMISING OPERATIONS The way is open for information automation to take the lead, as data rapidly becomes the next battleground in the war on efficiency and productivity. Manufacturers should take the opportunity to automate their data collection processes or make their manual data collection processes more efficient and robust. This can be implemented in the form of timed data collections, data collection workflows and more, all controlled and directed to give workers the information they need when they need it. As data is collected, it can then be further analysed in ways to provide real-time insight and alerts to workers. We now have the technology capabilities to effortlessly capture data in real-time, analyse that data in realtime using sophisticated algorithms, and present the result of that analysis in highly intuitive visualisations. This makes decision making much quicker and more effective, enabling critical decisions to be made in realtime to ensure that production processes are running optimally. In legacy manufacturing environments that do not have even a modest degree of digital maturity, much effort is spent monitoring stable processes so that we can be ready to catch abnormal or problematic situations. But today, that constant monitoring can be performed automatically. This exception-based approach to monitoring is a critical approach to eradicating operator inefficiency. It now becomes easier to be made aware of violations or problems in real-time and be able to act to prevent or avoid issues before the damage is done. Where processes are not running optimally, production teams can instantly gain insight into where problems lie, or where they are most likely to occur and intervene proactively before there is any impact on manufacturing performance.
ENJOY VIEWING THE WIDER PERSPECTIVE A CONTRAST IN ADVANCED TECHNOLOGY Even in highly automated industrial environments, it’s not uncommon to see process parameters, product quality checks and lab checks recorded manually, potentially even still on paper. In fact, it is fairly common to see. Monitoring production processes and quality simply aren’t on the same level when it comes to automation and technological innovation, and performance only suffers as a consequence. Advanced shop floor information technologies, such as manufacturing and quality intelligence solutions, help to boost manufacturing performance in real-time by optimising end-to-end manufacturing processes. Preventing small errors in production compounding, or eradicating unnecessary variability in a process produces less waste and less risk of creating subpar products which can damage consumer trust. When scaled up across the entire manufacturing lifecycle and all facilities, the net improvements can be significant. This is done in principle by ensuring that the right data is available at the right time in the right place to the right user and presented in a way that can ensure they are constantly making the most informed decisions. That relies on the effective automation of these data-related processes – from data acquisition, statistical analysis and visualisation. In outdated manufacturing environments, for any meaningful analysis of manufacturing operations, data must first be collected, prepared, imported and analysed
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As information collection and analysis becomes more automated, this also translates into wider scale insights on manufacturing performance across the company. Beyond the plant floor, quality professionals, operations managers, and C-suite executives can use the enterprise visibility attained through manufacturing and quality intelligence solutions to monitor and analyse automatically generated dashboards. These dashboards can be presented in real-time to show essential data and insights according to each user’s role, access permissions, and level of responsibility. Decision-makers can apply optimal adjustments and best practices from top-performing plants to all sites for enterprise-wide benefits. They can also compare quality across multiple sites, products, processes, lines, shifts, or production runs to identify continuous improvement opportunities that lead to global transformation and exponential cost savings. By unifying your data in a centralised, unified repository, you can gain the benefits of enterprise-wide visibility and operational intelligence, and gain consistent process and quality improvements as you prepare your organisation for the next steps in its digital transformation. Embracing information automation across all sectors is the key for manufacturers to understand and continue to future proof their operations, and ahead of competitors. infinityqs.com
| CHEMICAL INDUSTRY JOURNAL |
| tanks and vessels |
7-off Internal Coil Tanks for the Chemical Sector Project complete! Take a look at these 7-off, stainless 316, internal coil process vessels, fabricated bespoke for our customer. From initial concept to final delivery our expert in house design and fabrication team have manufactured these vessels bespoke to spec and on time for the customer project timeline. The vessels will now go on to final delivery at our customers Yorkshire based production facility. They will be part of a light chemical manufacturing plant, utilising the internal coils as temperature stimulators. We are proud to say this is yet another project fully completed in house, and made in Britain to the highest quality. Our purpose-built fabrication shop is 34.5m by 24.0m with an under hook height of 14.0m – enabling us to manufacture stainless steel vessels from as small as 50 litres right up to 180,000 litres. We use manual metal arc, MIG and TIG welding techniques, which are supported by both oxy-acetylene and plasma cutting. We pride ourselves on our ability to remain at the forefront of the industry in terms of quality and capability through continuous improvement in skills, machinery and fabrication techniques. All our vessels are fabricated to the highest level of quality excellence. We ensure this by following our ISO 9001 Quality Management System. We follow the BS EN 9606-1 standard for coded welding, with dye penetrant testing completed on all welds. After project completion, a hydrostatic water
fill test is completed on all vessels as a final assurance procedure prior to installation. Once completed, our installation team with over 100 years combined experience are on hand to conduct a safe and time efficient installation phase for your tanks. Transportation is handled by our long term key partners with experience, and equipment for large, abnormal loads. All work is carried out according to UK health and safety regulations with site surveys, risk assessments and method statements. From start to finish your project is in the hands of our experienced team, with thousands of completed projects under our belt, we are uniquely positioned to satisfy your requirements in a time efficient, safe and quality manner. If you would like any information on our fabrication capabilities, take a look at our new vessels page below. Alternatively, to speak to one of our dedicated team, email us at sales@tanksandvessels.com. No project is too big or too small! www.tanksandvessels.com/new-vessels
“Tanks & Vessels have supported our business over many years. All the way through from the initial project enquiry to manufacturing, testing, delivering and installing the finished product, they have made purchasing new and used stainless steel tanks a very simple and straight forward process” Engineering Manager
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Supplying the Chemical Processing Industries for over 40 years OVER 1000 NEW AND USED STAINLESS STEEL TANKS AVAILABLE IMMEDIATELY Stainless Steel Tanks: > > > > > > >
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| CHEMICAL INDUSTRY JOURNAL |
| distribution and logistics |
Thrive, not survive: Adding value at every touchpoint is key to tackling supply chain challenges Between climate change, Covid-19 and the Ukraine war, supply chains are now wedged deep into ‘survival mode’. When speaking to colleagues in the industry, many have felt like the last two years have been a blockbuster disaster movie – with each part trying to surpass the one before. This domino effect has been challenging for consumers, most certainly, but for distributors and manufacturers it is far more complex.
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| CHEMICAL INDUSTRY JOURNAL |
| distribution and logistics |
THE TIPPING POINT It is reported that 96% of all manufactured goods are directly touched by the chemical industry1. For every customer that relies on the distribution network, the pandemic has left issues with shipping containers that will take years to address. In the UK, Brexit has led to customs backlogs, with many hauliers steering a wide berth and driving up costs further. Then we have the war in Europe. Digital transport analysts Upply report that the war is not just a triggering factor in supply chains, but an aggravating factor that prolongs consequences over time2 – and we are inclined to agree. Fuel inflation, coupled with Ukraine as a major source of grain and other raw materials, means the conflict is impacting countries like Hungary, which manufactures fibres for meat and vegan products in the food industry. In pharmaceuticals, around 80% of all screening compounds used in drug R&D were made in either Ukraine or Russia3, causing further disruption. In road and transport, there’s a growing shortage of truck drivers in Lithuania, which has hampered the supply of raw materials like metal and steel4, while Russian embargos have impacted trade routes with the East. Adding fuel to the fire, supply chains were affected by China’s dual control policy last year, which focused on ensuring the country satisfied its own needs first. Lockdowns in the country are still causing silicon shortages – the second-most abundant metal on our planet. This not only has a major knock-on effect on chip and automotive manufacturing, but it also effects the production of silicone used widely in medical implants and deodorants in the pharma industry. Essentially, many of the raw materials the chemical industry and its supply chains rely on daily are sourced from this region. This instability will get worse before it gets better. The challenges are hampering Britain’s ability to grow and become independent, but this is where distributors can help. No matter what industry you are in now, ongoing challenges mean we are in a period where buying direct is not just inefficient but simply a bad business decision.
OUT WITH THE OLD, IN WITH THE NEW Businesses that are adapting to change quickly are using distribution services to navigate overseas supply chains on their behalf, while those that go direct are seeing goods being held back by hauliers, price surges, and have no way of sourcing an alternative when raw materials run dry. Choosing a distributor with warehouse partners across Europe and the UK – including hauliers with backup options (plan B, C, D and so on) – can help companies navigate the challenging environment we now find ourselves in. This includes understanding global customs regulations to seamlessly deliver goods to different regions. However, I want to make it clear to those in the industry that I do not believe the traditional distribution model works. In the past, distributors have been seen as a necessary evil, where companies often feel like they are paying for a job that they could probably do themselves. Atypically, they don’t focus on the customer and are locked into large contracts with one or two suppliers. The chemical industry now needs to look at distributors who do things differently – who add value at every touchpoint. If the past two years have taught us anything, it is that driving value back into the UK should be top of the agenda.
Karsten Smet Director, ACI Group.
“I want to make it clear to those in the industry that I do not believe the traditional distribution model works.” As such, distributors must now think about how to minimise their impact on the planet’s resources. For example, ACI Group has embarked on several sustainability programs to help the industry build a better, more agile supply chain network. This includes becoming the first distributor to gain the Social Value Quality mark – an award that aims to cultivate and recognise the highest known standards in values-led business – and enables us to understand how best to work towards carbon neutrality. In addition to sustainability-led goals, distributors must also increase transparency of services so that they are clear and measurable. This may include changing the way businesses are charged, so that they can spread their costs and adapt to a climate that is suffering from increased inflation and ever-rising rates. The chemical industry should find distribution partners that have invested in innovative technology to automate business areas. Not only does this help to reduce manual labour, but it also increases speed to market by minimising human error. As such, I believe technical innovation will soon begin to disrupt and blur the lines between distribution and IT. It is funny how we, as individuals, eventually find our way back to a place of comfort. I fell into distribution after developing my skills as a technologist as COO of one of the most innovative cloud providers in the UK. Now, I am leading ACI Group from the front and using innovative technology to disrupt the traditional distribution model for the better. acigroup.biz
ADDING VALUE THROUGH SUSTAINABLE INNOVATION
REFERENCES
In a recent Deloitte survey of 23,000 people worldwide, 72% believe that climate change is an emergency1. To reduce emissions, the chemical industry must adapt dynamically to changing customer needs. This requires building an agile business model – an ecosystem of partners that can add value to your business and supply chain.
1. Deloitte, Reducing carbon, fuelling growth: Lowering emissions in the chemical industry, June 2022
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2. Upply, Inflation is invading the entire supply chain, March 2022 3. Chemistry World, Ukraine’s chemicals industry survives weeks of war, April 2022 4. LRT, Shortage of drivers and substitutes – impact of Ukraine war on Lithuanian economy, March 2022
| CHEMICAL INDUSTRY JOURNAL |
| reach global |
TURKISH REACH; FINAL COUNTDOWN HAS BEGUN - LATEST UPDATES ON KKDIK & NEW TURKISH C&L INVENTORY WHILE TALKING WHETHER THE DEADLINE WILL BE EXTENDED… As the KKDIK registration deadline of 31/12/2023 is getting closer and closer, Turkish Competent Authority (Ministry of Environment, Climate, and Urbanization (MoECC)) continues to meet the experts within the sector on presentations and events regarding the progresses on the Turkish Chemicals Regulations. Although no official statement has been issued, MoEUCC has voiced their intentions through these meetings and webinars where they clearly declared that registration deadline will not be delayed. Quite the contrary, the Ministry has strongly pushing for the lead registrations to be completed by the end of 2022. Therefore, Lead Registrants are currently rushing to submit their dossiers on time. When a Lead Registrant submits its registration dossier, all other MBDF (SIEF) members are notified automatically. Companies approved by the Lead Registrant can consequently send their own joint submission dossiers. MoEUCC, is also communicating the latest developments in the registration processes to the chemical industry, and recently announced some updates on the Chemical Registration System (KKS), especially with regard to subjects of concern of the industry. One of them is regarding registration fee payment procedure. Until June the registration fees payment were carried out by a physical cash deposit to one pre-defined bank of Turkey. However, as of June, an online payment procedure has been established. Another subject of interest for all potential registrants was related to the language criteria. The MoEUCC recently announced that the Full Study Reports and other reports can be uploaded to the system in English, provided that all fields in the system for “Robust Study Summaries” and “Study Summaries”, are duly entered into the Chemical Registration System, and are filled in Turkish.
NEW GUIDANCES REGARDING CSR PREPARATION ON KKS Seven new guidance have been released on Ministry website to assist companies in fulfilling their obligations regarding the creation of a Chemical Safety Report and information requirements. Additionally, the Ministry has published a “Guidance on the Preparation of PPORD Dossiers”. These manuals comprise publications that describe the information requirements for substance properties, exposure, usage, and risk management measures, as well as chemical safety assessment, as defined by the KKDIK Regulation. In addition to a number of fundamental KKDIK procedures, the appropriate publications are defining specific scientific and/or technological approaches that should be implemented by the industry or approved institutions within the scope of KKDIK.
hazardous substances (alone or used in a mixture) which are exported to the Turkish market must be notified. The Chemicals Help Desk, where it is possible to access many guidelines and information regarding the regulations, is kept up to date by the Ministry. Classification and labelling notifications of hazardous substances submitted to the Ministry’s online KKS system by the manufacturer/importer of the substances are now available online under KIMVES section of the Chemicals Help Desk website. It has been stated that the notifications being published on this area are based on company declarations. The Ministry does not accept any legal responsibility regarding the use of the information contained therein.
CHEMICAL SAFETY ASSESSMENT THROUGH CSARS According to the KKDIK Regulation, a Chemical Safety Assessment (CSA) shall be performed by companies placing substances on the Turkish Market in quantities greater than 10 tons per year and a Chemical Safety Report should be completed and included in the Registration Dossier. There is a Chemical Safety Assessment and Reporting System (CSARS, with Turkish acronym - KGDRS) integrated into Chemical Registration System - KKS (Turkish acronym) which enables preparing the CSR (KGR with Turkish acronym). In order for the CSR sections 8-10 (Exposure Assessment and Risk Characterization) to be fully formed through the CSARS system; substance determinants, molecular weight, physical state, vapor pressure, Partition Coefficient-Log Kow, water solubility, biodegradability, PNEC and DNEL information must be entered to the registration dossier. Also, the ‘’3.5. Usage and Exposure Information’’ parts of the registration dossier is essential to be completed for the creation of CSR parts 9-10 in full. In case of this information is missing in the registration dossiers, parts 9-10 of the CSR cannot be automatically generated by the system. RGS Group based in Brussels, Belgium with subsidiary in Istanbul, Turkey is representing global companies located in over 55 countries as a local Only representative through its Turkish presence. As a leading company, RGS also transfers 14 years of regulatory experience predominantly in EU REACH experience to its operations in Turkey. Do not hesitate to contact RGS, if you need compliance with Turkish Chemicals Regulations or more details on our services. REACH Global Services Group Pınar Ozgun Yavas Deputy Director www.reach-gs.eu
TURKISH C&L INVENTORY IS NOW AVAILABLE ON KIMVES SECTION IMPLEMENTED TO THE CHEMICALS HELP DESK According to the By-Law on Classification, Labelling and Packaging of Substances and Mixtures (SEA Regulation),
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Each customer is a “project” deserving a tailor made solution that best suits its needs!
• EU REACH & Turkish KKDIK OR Services • SIEF-Consortia Management • Chemical Safety Report & SDS Authoring • EU Cosmetics Regulation RP Services • CPNP Notification• PIF Preparation & Safety Assessment • K-REACH, CSCL, MEP Order 7, TCSCA Representations
| CHEMICAL INDUSTRY JOURNAL |
| charles river |
Navigating Endocrine Disruptor Testing Under REACH Endocrine disruptor (ED) testing has gained importance for chemical companies since 2018 with the introduction of EFSA and ECHA guidance for agrochemicals and biocides. With discussions ongoing around thyroid adversity and the potential neurotoxicological impact, agrochemical and biocide manufacturers have been under increased pressure, which has further complicated the initial registration or renewal of biocides and pesticides. Chemical companies are awaiting confirmation on the anticipated addition of endocrine disruptor hazard categories firstly to CLP (classification, labelling, and packaging) as well as an update of the information requirements for REACH (registration, evaluation, authorisation, and restriction of chemicals) regulations, causing further uncertainty around data requirements.
WHAT COULD THIS MEAN FOR CHEMICAL COMPANIES? With the delay of hazard classes and REACH amendments, chemical manufacturers are faced with difficult questions, such as: What testing will be needed for compounds that are in development, and for substances that have been registered? What data gaps will need addressing? What are the costs associated with the required testing and how long will these studies take?
an appropriate format, to simplify endocrine disruptor identification and minimize exposure of both humans and the environment.
DEALING WITH SHIFTING TIMELINES Firstly, there will be a revision or an update to the current CLP regulations to introduce hazard classes for endocrine disruption. Once these hazard classes are defined then the data requirements for industrial chemicals under REACH can be updated to address these hazards. The updates to CLP regulations are planned for the second half of 2022, however, this date has already been moved back more than once. If the CLP changes go ahead in the third quarter of 2022, the REACH revision proposals would follow in early 2023. Since both are interlinked and clear timelines are not defined, manufacturers and developers are experiencing planning challenges.
Will there be a grace period before the new requirements apply? Will they test in-house or outsource? The expected demand for endocrine disruptor studies is anticipated to outstrip capacity in the short-term leading to limited study availability. These combined factors impact budgets, timelines, revenue, and profit.
WHAT DO WE KNOW? In October 2020 as part of the European Green Deal, the European Commission published the chemical strategy for sustainability with the subtitle -- Towards a Toxic Free Environment. Within this, they highlighted that endocrine disrupting chemicals required specific attention. They also highlighted the fragmented nature of the EU regulatory system in relation to endocrine disruptors. The European Commission will most likely look to ensure that sufficient information is made available, in
Figure 1: OECD CF= OECD Conceptual Framework for Testing and Assessment of Endocrine Disrupting Chemicals as described in OECD GD 150
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| CHEMICAL INDUSTRY JOURNAL |
| charles river |
Two proposals for additional information requirements have been presented by the European Commission adding in vitro and in vivo mechanistic studies starting at the low tonnage band requirements and expanding testing for in vivo adversity at the high tonnage bands (see Figure 1, opposite page, outlining current proposals). The chemical Strategy for Sustainability the Commission further sets out a preventive generic approach to risk management ensuring that endocrine disruptors are banned in consumer products. Although substances can already be identified as substance of very high concern (SVHC) based on endocrine disrupting properties, workers’ protection will be further strengthened by introducing endocrine disruptors as a separate category of SVHCs under REACH.
WHAT CAN COMPANIES DO TO PREPARE? Many manufacturers don’t have the luxury of waiting indefinitely on regulations to be finalized. To plan properly for testing budgets and to accurately estimate timelines for substance registrations, companies are looking for steps they can take now to help them prepare. One approach that could be useful is to look at your current portfolio of existing substances to identify potential endocrine disruptor issues. Similarly, any new actives in development could be evaluated early on to identify ED risk. One solution is to use ED screening studies to gather initial data which would then allow you to prioritize your substances, both new and in development, based on potential concern. Screening can identify where further data may be required and it can also help pinpoint where adaptations could be needed
to development pipelines or where groupings can be made of existing substances to enable a read-across approach.
ENDOCRINE DISRUPTOR SCREENING The first level of endocrine disruptor screening would employ read-across, QSARs, and/or other in silico predictions. The next step, on identification of problematic compounds, would be to begin in-vitro studies to provide usable data. In-vitro endpoints include estrogen, androgen, and steroidogenesis (EAS) modalities. The fourth addition is T or thyroid modality. Endocrine screening tests can be shorter in duration, use less test item and carry a lower cost than full GLP studies. This allows manufacturers to make an intelligence-led evaluation of risk without making a larger commitment to time and budget. By screening early on, you can take a strategic approach to your testing plan. Screening can give you a more rounded view of your products. By employing good product stewardship, you are better equipped to make informed business decisions around your renewal and registration plans. You may decide to stop development of a compound which carries a high ED risk potential to save costs further down the line. You can also be proactive and prioritize crucial products where you identify additional testing requirements to fill dossier gaps. To find out more about how Charles River can help you navigate the evolving world of endocrine disruptor testing PARTNER WITH US
Supporting Your Chemical Testing With our unparalleled global safety assessment expertise and regulatory know-how, we can help you with both partial or full testing support, risk assessment, and regulatory services to complete your submission on time. No matter the size of your business or the number of registrations in your portfolio, we’re here to help.
Learn more at www2.criver.com/chemicals
SA-REACH-CIJ-HP-Ad.indd 1
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| CHEMICAL INDUSTRY JOURNAL |
| news |
Navigating antimicrobial regulations Tara Conley, Global Director of Regulatory Affairs, Microban International, discusses how global regulations impact antimicrobial development, and the implications for chemical manufacturers. Microbial growth on products and substances can result in a plethora of challenges – such as staining, odours and biodegradation – that are difficult to tackle without addressing the cause. For example, mould is a recurrent problem in damp environments – especially bathrooms and kitchens – leading to end-users disposing of and replacing products prematurely. In addition, the global pandemic has really shone a light on the concept of cleanliness, with many consumers expressing concerns about visiting businesses, travelling on public transport or reusing products perceived as unhygienic.
A LASTING BENEFIT Tackling microbes can be costly for both consumers and the environment. This is driving the market for builtin antimicrobial technologies and coatings, a sector which is expected to soar by 7.1% CAGR from 20212030.1 Antimicrobials can help combat the multitude of problems associated with microbial growth, so it is no wonder that these technologies have been adopted for various applications, from activewear to medical equipment. One recent study found that 64 percent of consumers are now willing to spend more on goods with built-in antimicrobial product protection,2 so integrating these technologies into products can undoubtedly provide a competitive edge for chemical manufacturers and retailers. Antimicrobials work to destroy or inhibit the growth or reproduction of a broad spectrum of microorganisms, including bacteria, fungi and moulds, and can be incorporated into a variety of materials, either directly into the chemical formulation during manufacture or applied on surfaces to provide a protective layer.
BIOCIDAL REGULATIONS Antimicrobials are becoming hot commodities in many industries but, before investing, it is important for manufacturers to only partner with a trusted antimicrobial company with the experience to provide efficacious and trusted technologies. Antimicrobials are tightly regulated by national governing bodies such as the Biocidal Product Registration (BPR) in Europe and the Environmental Protection Agency (EPA) in the USA. These organisations control the type of application for which each antimicrobial product can be used, set levels for acceptable use in those applications, and provide parameters to ensure consistent marketing of these technologies to avoid them being misused or mis-sold. Biocide regulations – as with any industrial chemicals regulations – are frequently reviewed and updated based on new scientific research and, with new greener technologies on the horizon, it is important to keep up to date with changes that could impact the
antimicrobials market. Fortunately, partnering with a trusted additives provider can help to make light work of navigating these regulatory guidelines, as they are able to offer advice on how to correctly manufacture, market and sell antimicrobial products and articles treated with antimicrobial additives.
WHAT TO LOOK FOR WHEN CHOOSING AN ANTIMICROBIAL PARTNER An antimicrobial company should be able to navigate the regulatory landscapes necessary to bring effective products to the market. This can mean registering and defending the active chemistries or biocidal products under these regulatory regimes. The antimicrobials provider should do this by providing supporting environmental and human health information to demonstrate that the chemistries can be used safely by manufacturers and consumers, and shepherding the registrations through to completion to allow products to be sold, used and distributed.
DEMONSTRATING THE NEED FOR ANTIMICROBIALS An antimicrobials provider should also demonstrate the need and efficacy of their technologies for different applications. Some companies have touted materials such as PVC or vinyl as having a natural tendency to ward off microbes, suggesting that the use of antimicrobials may be unnecessary. However, no surface is completely resistant to microbial adhesion; even inert plastics can harbour germs and allow biofilm formation. These materials are not recognised as biocides by regulatory bodies and therefore companies must be very careful in their marketing of these materials, since claims of antimicrobial efficacy may be construed as biocidal claims requiring registration of those chemistries. Also, while it may be true that certain surfaces – such as those that are rougher, hydrophobic, rich in nutrients or coated by surface conditioning films – may succumb to microbial contamination more readily, it is also dependent on the type of organism, the application for the surface, and the size of the initial colony of organism. Instead, the addition of established antimicrobial technologies can ensure that these materials are protected from the growth of microbes.
ANTIVIRAL CLAIMS Regulatory requirements around antimicrobials have come to the forefront during the pandemic, as seen not only by the number of antiviral products on the market, but also by the number of enforcement actions taken against companies making unsubstantiated or egregious claims at a time of heightened consumer concern. Even with expedited reviews to address emergency use of
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| CHEMICAL INDUSTRY JOURNAL |
| news |
antiviral technologies, providers of such technologies still needed to generate data showing antiviral and antimicrobial efficacy, and in some cases, undertake robust product registrations to bring those products to market. It is also important to note that WHO recommendations state that the best way to prevent the spread of viruses between surfaces is to clean and disinfect them.3 Antimicrobial technologies are not intended to replace these cleaning practices – and should not be marketed as such – but rather supplement them by keeping exposed surfaces cleaner in between cleans, cumulatively reducing the viral load and growth of microbial contaminants.
A PUSH FOR SUSTAINABILITY AND SAFETY Part of the registration process for any antimicrobial additive at the national level is a review of the environmental impacts of that chemistry, including potential contributions to pollution or their ability to bioaccumulate in the food chain. Regulatory agencies evaluate the environmental and human health profiles of the additives with respect to their use and manufacture, and certifications from organisations such as bluesign® for textiles also identify environmentally preferred solutions. The best antimicrobials providers are those that are forward-thinking and committed to sustainability, and supply additives with minimal environmental and human health impacts. As the world shifts towards sustainability, green initiatives and combating climate change and unnecessary waste, choosing environmentally friendlier chemistries can effectively support these objectives.
SUMMARY Built-in antimicrobial technologies and coatings can provide significant benefits for many products, and chemical manufacturers should focus on scientifically proven chemistries that have been effectively tested and reviewed for safety and efficacy. Partnering with a leading antimicrobial additives company that understands and remains current and compliant with relevant regulatory guidance is the best way for manufacturers to ensure that antimicrobial-treated products are designed and marketed correctly in their region of sale.
REFERENCES 1. Allied Market Research (2021). Antimicrobial Additives Market Drivers, Trends | Analysis 2030. Retrieved 17 June 2022, from https://www. alliedmarketresearch.com/antimicrobial-additives-market 2. Multi-sponsor surveys. (2020). Antibacterial Products Study 3. World Health Organization. (2022) Coronavirus disease (COVID-19): Cleaning and disinfecting surfaces in non-health care settings. Retrieved 17 June 2022, from https://www.who.int/news-room/questions-and-answers/item/ coronavirus-disease-covid-19-cleaning-and-disinfecting-surfaces-in-nonhealth-care-settings
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| CHEMICAL INDUSTRY JOURNAL |
| news |
Decarbonisation technology proven at Waste-toEnergy plant Danish researchers have shown it’s possible to remove most of the carbon dioxide (CO2) from waste incinerator emissions. A key objective of net zero is to develop and exploit decarbonisation technologies such as carbon capture and storage (CCS) and carbon capture, utilisation and storage (CCUS). A pilot plant is now operational in Copenhagen using a novel gas monitoring technology to optimise plant efficiency. Researchers from the Technical University of Denmark (DTU), are working on a process which captures carbon dioxide (CO2) from emissions, using advanced gas analysers from industrial measurements firm Vaisala to measure carbon capture efficiency and CCUS viability. The pilot plant is based at the Amager Bakke Waste-toEnergy Plant, one of the largest combined heat and power (CHP) plants in northern Europe, with the capacity to treat 560,000 tonnes of waste annually. (It features several innovations including a rooftop artificial ski slope). The pilot plant was developed to capture CO2 from the emissions of processes such as wastewater treatment, biogas production, anaerobic digestion and waste incineration. However, the researchers are also investigating ways in which CO2 can be both captured and utilised. Prior to its installation at Amager Bakke, the pilot carbon capture plant was operated at a wastewater treatment plant. “The technology itself is not new,” explains DTU researcherJens Jørsboe. “However, the focus of our work has been to lower the cost of carbon capture, so that it can become economically feasible.”
HOW IT WORKS Exhaust gas from the Amager Bakke incinerator is passed through an electrostatic precipitator (ESP) to remove particulates, NOx compounds are removed by selective catalytic reduction (SCR) and a scrubber removes oxides of sulfur. High levels of CO2 remain in the flue gas and
the main purpose of the pilot carbon capture plant is to investigate the feasibility of its capture. To achieve this, the gas is passed upwards through a column packed with beads and a monoethanolamine (MEA) solvent which scrubs the CO2 from the gas. The solvent is then passed to a desorber which removes the CO2, now almost pure, and regenerates the MEA for re-use. As a research project the produced CO2 is currently still vented to air, but on a commercial basis there are many different industrial applications in which CO2 can be utilised. For example, CO2 can be reacted with hydrogen in the Sabatier process to produce methane (a gas fuel) and water, at elevated temperature and pressure, in the presence of a nickel catalyst. This can be a green method for manufacturing fuel if the hydrogen is generated by electrolysis using renewable energy – from solar, biogas or wind power for example. CO2 is also used in a wide variety of other industries including food and beverages, refrigeration, medical, horticulture, firefighting, welding etc., so a variety of potential markets are available if CO2 can be produced on a commercial quality and scale.
MONITORING CARBON CAPTURE EFFICIENCY The optimisation of the carbon capture process can only be achieved if CO2 concentrations is continuously monitored before and after the carbon capture process. The world’s first inline CO2, humidity and methane monitor was developed by Vaisala in Finland prior to the pilot plant construction. Exhaust gases from incinerators can be corrosive and potentially explosive, so in the past it has not been possible to conduct in-line monitoring. Until recently, the only solution was to extract samples for analysis outside of the process, but this method is not suitable for process control and optimisation, and has a number of inherent flaws, such as the need to remove humidity from the sample line and a requirement for frequent re-calibration. The development of Vaisala’s multi-gas probe, the MGP261, resolved these monitoring challenges, especially when it was followed by sister product the MGP262, which was adapted for measuring high concentrations of CO2 and
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| CHEMICAL INDUSTRY JOURNAL |
| news |
therefore ideal for the continuous inline monitoring of almost pure CO2 after the pilot plant’s desorber. The pilot plant employs three Vaisala probes in total, with the MGP261 monitoring incoming incinerator exhaust gas, and the MGP262 measuring the purity of the extracted CO2. The third probe is a Vaisala CARBOCAP® CO2 probe, the GMP251, which checks the levels of CO2 (after carbon capture) in the pilot plant’s exhaust gas.
MONITORING TECHNOLOGY All three monitoring probes contain CARBOCAP® technology which utilises an electrically tunable Fabry-Pérot Interferometer (FPI) filter. In addition to measuring the target species, the micromechanical FPI filter enables a reference measurement at a wavelength where no absorption occurs. When taking the reference measurement, the FPI filter is electrically adjusted to switch the bandpass band from the absorption wavelength to a non-absorption wavelength. This reference measurement compensates for any potential changes in the light source intensity, as well as for contamination in the optical path, which means that the sensor is highly stable over time. Within the MGP261 and the MGP262, humidity and CO2 are measured with the same optical filter, and a second optical channel measures methane. In many ways, this combines the analytical power of a laboratory spectrometer with the simple, rugged design of an industrial process control instrument. Jens says: “We have been delighted with the accuracy and reliability of the multigas probes; not least because they have enabled us to learn a great deal about the management of flue gas from waste incineration. Much is known about the emissions from fossil fuel combustion, but less information is available on the emissions from waste incineration.
“The technology employed by the Vaisala probes is also helping to minimise operational costs because by effectively calibrating themselves the probes’ service requirements have been minimal and downtime is avoided.”
CARBON CAPTURE With the benefit of continuous inline monitoring, the researchers have been able to optimise carbon capture performance following an evaluation of 12 different pilot plant configurations. Having proven the viability of the carbon capture process, the next step was to evaluate the relative advantages of carbon storage and utilisation. Jens adds: “At the moment, utilisation of CO2 is the more expensive option because of costs associated with the required further refinement of the CO2, so the owners of the Amager Bakke plant are planning to apply for 1.5 billion DKK ($230 million USD) for a CCS plant capable of capturing 500,000 tonnes of CO2 per year – if the right regulatory framework and sufficient funding is provided by the Danish state. This plant would employ the same amine scrubbing process that has been proven by the pilot carbon capture plant.” The incineration of 1 tonne of municipal waste (MSW) is associated with the release of between 0.7 and 1.7 tonnes of CO2, depending on the content of the waste. Consequently, energy generation from waste incineration is more carbon intensive than the burning of fossil gas, so carbon capture offers an opportunity to manage the growing requirement for municipal waste treatment without generating unacceptably high levels of GHGs. Jens believes this technology could be applied at every waste incinerator in the world, around 2,500 WtE plants, with a disposal capacity of around 400 million tonnes of waste per year. It should also be possible to harvest residual heat, which could be transferred to local industry or a district heating network.
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| news |
Public consultation on extending the UK REACH transitional registration deadlines
The Department for Environment, Food and Rural Affairs (Defra) has published a consultation on extending the UK REACH submission deadlines for transitional registrations. In December 2021 Defra committed to exploring alternative arrangements for UK REACH transitional registrations in order to support chemical businesses, whilst upholding a high level of human and environmental health protection in line with international commitments. It will take time to fully develop an alternative transitional registration model and, if the decision is made by Ministers to proceed, to develop and pass the necessary legislation. It will also be necessary to allow industry time to comply with new arrangements. Therefore, Defra also committed to consult on extending the deadlines for providing the full registration data. This public consultation is seeking views on options to extend those current deadlines for registration, depending on tonnage and hazard profile. These are: October 2023 for substances included on the EU REACH candidate list before UK REACH came into effect; substances that are carcinogenic, mutagenic or toxic for reproduction and manufactured or imported in quantities of 1 tonne a year or more; substances that are very toxic to aquatic life and manufactured or imported in quantities of 100 tonnes or more a year; and all substances manufactured or imported in quantities of 1,000 tonnes or more a year. October 2025 for substances added to the UK REACH candidate list before the above submission deadline; and all substances manufactured or imported in quantities of 100 tonnes or more a year.
October 2027 for all substances manufactured or imported in quantities of 1 tonne or more a year. The first of the current registration submission deadlines is October 2023, therefore amendments to the current legislation are necessary to extend the deadlines to ensure there is sufficient time for substantive development of the policy, and to make operational and legislative changes to implement the new model. Industry will also need time to prepare for compliance with it. Extending the deadlines will reduce the likelihood of companies making nugatory investments in complying with current deadlines and data requirements. It will allow them time to plan their business decisions in relation to the extended deadlines. Defra is also seeking views on extending the dates for the Agency (HSE) to carry out compliance checks on 20% of registration dossiers. Comments must be submitted to the consultation by 1 September 2022. Responses to this consultation will be used to inform decisions on changes to the UK REACH registration submission deadlines. Defra will not introduce new secondary legislation extending the current deadlines until responses to this consultation have been considered. Defra has also published a written statement from the Defra Secretary of State on the consistency of the amendments proposed in the consultation with the aims of the UK REACH legislation. More information at hse.gov.uk
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114.818
Pu Am Cm Bk Cf Es Fm enantioselective catalysts Plutonium
2 5
Nitrogen
Si
Indium
Copernicium
Dysprosium 2 8 18 32 27 8 2
In
200.59
2 8 18 32 32 18 1
2 8 18 3
69.723
Mercury
162.5
Terbium
97
111
49
112.411
2 8 18 32 18 1
14
Gallium
Cd
Gold
158.92535
2 8 18 32 25 9 2
Au
2 8 18 18 2
Ga
Cadmium
196.966569
Darmstadtium
Gadolinium 2 8 18 32 25 8 2
79
195.084
157.25
Europium
2 8 18 32 17 1
31
Zinc
Silver
2 8 3
26.9815386
2 8 18 2
65.38
107.8682
Platinum
Meitnerium
151.964
Samarium
Pt
192.217
109
Ag
Palladium
macromolecules 61
C
12.0107
Carbon
Aluminum
Zn
Copper
Pd
Iridium 2 8 18 32 32 14 2
63.546
Nickel
Rhodium
Osmium 2 8 18 32 32 13 2
58.6934
Cobalt
Ruthenium
Rhenium 2 8 18 32 32 12 2
58.933195
Iron
(98.0)
183.84
2 8 18 32 32 11 2
55.845
Technetium
Tungsten
144.242
U
2 8 18 13 2
Fe
54.938045
Nd Pm Sm
Uranium
26
Manganese
95.96
2 8 18 22 8 2
238.02891
2 8 13 2
7
2 4
TM
sputtering targets tungsten carbide
43
Molybdenum
Neodymium 92
2 8 18 13 1
51.9961
Chromium
Dubnium
60
25
rare earth metals
mesoporous silica MBE
42
2 8 13 1
ultralight aerospace alloys
180.9488
140.90765
Cerium 90
quantum dots
Ce
59
2 8 18 12 1
Cr
Tantalum
Rutherfordium
2 8 18 19 9 2
24
92.90638
178.48
2 8 18 32 18 9 2
2 8 11 2
Niobium
epitaxial crystal growth drug discovery
Nb
Hafnium
Actinium
58
V
Zirconium
Lanthanum 2 8 18 32 18 8 2
23
47.867
Yttrium
137.327
88
Y
2 8 10 2
Titanium
88.90585
Barium 2 8 18 32 18 8 1
Sc
2 8 9 2
Scandium
87.62
Cesium
Fr
39
Strontium
132.9054
87
2 8 18 8 2
40.078
85.4678
55
21
Calcium
Rubidium
3D graphene foam
nanodispersions
2 8 8 2
Al
2
Helium
Boron
13
2 8 2
isotopes
39.0983
Potassium
37
B
He
metal carbenes
6
10.811
Beryllium
nanogels
2
4.002602
2 3
bioactive compounds
9.012182
Lithium
Na
Be
5
2 2
gold nanoparticles
III-IV semiconductors
screening chemicals
alternative energy
buckyballs
Now Invent!
metallocenes BINAP
conjugated nanostructure
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