Occupational chemical exposure and risk estimation in process development and design

Each year more people die from diseases caused by work than are killed in industrial accidents. Therefore, methods are needed to evaluate occupational health hazards as early as possible when the process is still under development. A method for estimating inhalative exposures and risks in petrochemical and related plants is presented. The method is simple and suffices with the limited data availability during the early design stages.The steps of the method, which utilizes preliminary process flow diagrams are as follows: first the fugitive emissions and process plot areas are estimated based on precalculated process modules representing the typical process sections (such as a distillation unit). Chemical concentration in the air is then calculated based on the wind velocity probability and the estimated process cross-sectional area. For this purpose a typical wind velocity distribution in the area is used. The worker risk of exposure to chemicals is evaluated either based on the concentration in air by using the hazard quotient method or calculating the carcinogenic chemicals intake and the resulting risk of cancer. The values are compared to the benchmarks.As a result the process route health characteristics such as fugitive emissions rate, critical wind speed, chemical concentration in air and intake amount as well as the corresponding risk of exposure are produced. By using statistical meteorological data, health risks of occupational exposure can be estimated more realistically as probabilities. The approach is capable of comparing alternative processes to select the concept which is inherently occupationally healthier. Using this method, the exposure problems of a process can be identified earlier and proper decisions can be made early in process development or predesign stage.The concentration-based method is demonstrated by a case study of six competing manufacturing routes for methyl methacrylate (MMA). The C3 is found to be the most harmful alternative to health. Both concentration-based and intake-based methods are applied. The study indicates that the intake-based risk estimation benchmark is stricter than the exposure limit-based benchmark for carcinogens.     

Land management in rural Burkina Faso: the role of socio‐cultural and institutional factors

Farmers in the Sahel have been acknowledged for reclaiming degraded lands and improving food security by ingeniously modifying traditional agroforestry, water, and soil management practices. Despite the advantages offered by this range of farming techniques, their adoption rate is influenced by several factors. Using multivariate probit models and a correlation coefficient, this article examines the factors influencing the adoption of five land management practices based on 220 household and 40 farm surveys in four adjacent rural communities in southern Burkina Faso. The model results indicate that household labor force, education of household head, land tenure security, livestock holding, and membership in farmers’ groups influence the adoption of zaï practice, composting, improved fallow, stone bunds, and live hedges. However, two of the surveyed factors ‐ number of farms and visit by agricultural extension staff during the 12 months prior to the survey ‐ were not significant. Furthermore, a significant correlation was found between different land management practices, e.g., the decision to practice zaï is significantly linked to that of live hedges and composting. Zaï practice and stone bunds are considered labor intensive, which explains their significant correlations with household labor force at the 1% and 5% levels of significance, respectively.     

Inherent occupational health assessment during preliminary design stage

Chemical process routes can already be assessed as early as in the development and design phases. Process screening should not look at economic and technical aspects only, but also the safety, health, and environmental performances. In this paper, a method called the Health Quotient Index (HQI) is presented for the preliminary process design phase. The HQI provides a simple approach to quantify workers' health risk from exposure to fugitive emissions e.g. in petrochemical plants. The method utilizes process data from flow sheet diagram, which is already available at the preliminary design stage. Since the mechanical details of the process are still unknown, a database of the precalculated fugitive emissions for typical operations in chemical plants was created to simplify the assessment. The HQI can be used to rank alternative process concepts or to quantify the risk level of processes. As a case study, six process routes for producing methyl methacrylate are discussed. Three health indexes are compared in the case study. The HQI is able to highlight the difference of hazard levels between the routes better as a result of more detailed assessment of the exposures.     

Inherent occupational health assessment during basic engineering stage

Each year more people die from work-related diseases than are killed in industrial accidents. Therefore it is essential to evaluate occupational health aspect during the process design. Early evaluation of safety, health, and environmental (SHE) performance is advantageous, since the opportunities to make the process inherently benign are greater and the cost therefore lower. The methods for occupational health assessments need to be tailored to specific design stages, since the data availability is changing as the design proceeds. In this paper, an index-based method called the Occupational Health Index (OHI) is presented for the basic engineering stage. The OHI is the final of the three methods in series proposed for health assessment in development and design stages. The OHI is based on the information available in piping and instrumentation diagrams (PIDs) and the plot plan. Four health aspects are considered; chronic inhalation risks to noncarcinogens and carcinogens, acute inhalation risk, and dermal/eye risk. The index is demonstrated on separation system of a toluene hydrodealkylation process. The assessment results allow the level of occupational health risks to be evaluated, the sources of exposures be detected, and corrective actions taken in a focused way.     

Estimation of chemical concentration due to fugitive emissions during chemical process design

Fugitive emissions are not an environmental concern alone, but are also a health concern. From occupational health standpoint, fugitive emissions are the main sources of origin of the continuous exposure to workers. Operating plants regularly measure release and concentration levels through a plant-monitoring program. However, for processes which are still ‘on paper’, predictive estimation methods are required. Therefore, three methods for estimating concentration of the fugitive emissions are presented for the process development and design phases of petrochemical processes. The methods estimate the fugitive emission rates and plant plot dimensions resulting to fugitive emission concentrations. The methods were developed for the type and amount of information available in three process design stages; conceptual design, preliminary process design, and detailed process design. The methods are applied on a real benzene plant; the estimated benzene concentrations are compared to the actual concentration measured at the plant. The results show that as the information mounts up during design, the concentration estimate becomes more accurate. The results indicate that the methods presented provide simple estimates of fugitive emission-based concentrations during the design stages.     

Evidence of rich microbial communities in the subsoil of a boreal acid sulphate soil conducive to greenhouse gas emissions

The largest areas of acid sulphate (AS) soils in Europe are located in Finland, where 67,000–130,000 ha of AS soils are in agricultural use. In addition to their acidifying effects on waters, AS soils might be a significant source of greenhouse gases. In this pilot research, carbon and nitrogen content and microbial activity were studied in an AS and a non-AS soil. Large carbon and nitrogen stocks (110 Mg C_org ha^?1 and 15 Mg N_tot ha^?1) as well as high substrate induced respiration (33 μg CO₂–C g^?1h^?1) were found in the C horizons of the AS soil but not in the non-AS soil. High microbial activity in these horizons of the AS soil was further confirmed by the measurement of dehydrogenase activity, basal respiration, the numbers of culturable bacterial cells, and the ratio of culturable to total numbers of cells. Still, the denitrifying enzyme activity was very low in the anaerobic horizons of the AS soil, indicating the prevalence of microbes other than denitrifiers. We suspect that the microbial community originated with the genesis of AS soil and has been supported by the large stocks of accumulated carbon and mineral nitrogen in the C horizons. If these permanently water-saturated subsoils are exposed to oxygen and their microbial activity consequently increases, large carbon and nitrogen stocks are likely to be mobilised, resulting in increased emission of greenhouse gases. Additional studies of boreal AS soils are needed to assess their potential contribution to increases in greenhouse gas fluxes at the local, regional, and global scales.     

Investment Evaluation of an Integrated Steel Mill using Multiple Criteria

A conventional steel manufacturing process generates considerable amounts of reject streams and secondary raw material. These streams are either recycled back to the process or treated as waste. Recycling affects negatively on the production yield and on the controllability of unit operations. Waste represents considerable cost unless utilized in another production process as raw material. In these streams, there exists a potential to use the chemical elements more effectively. Therefore, it might be interesting to find an economical technical solution to collect the streams and increase steel production.

Investments on process equipment are typically evaluated using conventional economic figures, like payback time, Net Present Value (NPV) etc. The problem with these practices is, that they consider only numerical aspects. Non-numerical and non-economical criteria are hard to cater to the evaluation. Still, they may affect on the investment profitability in the long run. Such criteria include environmental friendliness or the aspects of process integration.

The article presents a comparison of a conventional steel manufacturing process with one reject stream processing alternative. A target in the process modification is to optimize the use of material and energy within the site. The comparison is based on a balanced set of criteria that affect on the efficiency of an investment. The use of these criteria is a part of the new methodology that has been developed to evaluate investments on integrated process sites. In addition to the criteria, the complete methodology includes: 1) connection of company’s strategic issues into technical design and decision making, 2) optimization of the process and calculation of process potentials (differences in the performance values between the existing process and the modified process) through the use of process integration methodologies and 3) use of decision-making aids. The research is a part of Finnish National Technology Program, “Process-Integration 2000–2004”.