Loss prevention in turnaround maintenance projects by selecting contractors based on safety criteria using the analytic hierarchy process (AHP)

Turnaround maintenance (TAM) is a usual plant shutdown that is done by process industries to perform asset inspections, repairs, and overhauls. TAM engineering projects are needed on a periodic basis to optimize a plant's performance. Process industrial plants usually don't have enough in-house manpower to carry out needed TAM jobs; it is not uncommon for a process industrial plant to outsource its TAM manpower supply to external contractors. This will create a peculiar management challenge regarding how to assure orientation of safety practices for the newly hired labor. Although accidents during process plant shutdowns may have severe consequences, the safety management systems in place for many companies only cover normal operations and few explicitly address TAM projects. Usually, contractors are evaluated from a safety perspective after handling the project by monitoring safety indicators such as number of injuries, incidents, etc. This paper emphasizes safety attributes to be included in selecting contractors at the bidding stage to assure loss prevention and better safety orientation during TAM implementation. The paper starts with reviewing TAM literature and defining main needed safety attributes to prequalify contractors. It develops an analytic hierarchy process (AHP) model that is applied to rank TAM contractors' selection. A case study is presented for a petrochemical plant in Saudi Arabia to demonstrate the AHP model.     

Recyling of plastic wastes via pyrolysis

Pyrolysis for the simultaneous generation of oils and gases can be convenient to obtain hydrocarbons and even to recover crude petrochemicals or to generate energy from waste plastics. A Gray–King apparatus has been used to pyrolyze waste polyethylene (PE), polystyrene (PS), both separately and with different compositions. Thermogravimetric analysis of waste plastics indicated the critical temperatures, which should be effective for pyrolysis. The chosen heating rate was low in order to achieve higher liquid yields. The results showed that waste PS yielded higher liquid, and waste PE yielded higher gaseous products. The dominant liquid product of PS waste was styrene whereas for waste PE, prophenylbenzene was the dominant pyrolysis product.     

Total site: wastewater minimization: Wastewater reuse and regeneration reuse

Analysis of technological wastewater streams in a refinery and petrochemical complex was carried out. Wastewater flowrates, temperatures, pH and pollutant contents were measured. Regarding the characteristics of the individual waters, possible connections between water outflows from the processes or process units and potential water consumers were determined. Possibilities to reduce the flowrate of technological wastewater with wastewater reuse or preliminary regeneration and reuse were found. The consumption of fresh water could be lowered by 11.2 m³/h, reducing the treatment system load and prolonging its residence time by 7%. The payback period for the changes proposed in the petrochemical plants is 6 months with annual savings of US$27 630. The payback period for the changes proposed in the refinery is 11 days with annual savings of US$15 500.     

Energy futures and green chemistry: competing for carbon

Global energy demand is expected to increase from the current 400 ExaJ per year to as much as 700–1,000 ExaJ per year by the middle of this century. If fossil carbon resources continue to make up the bulk of the energy supply, not only will atmospheric carbon dioxide increase to levels not seen for the past 30–35 million years, but depleting fossil carbon resources will become increasingly less available for other purposes, particularly the production of chemicals on which society now depends. The chemical process industries are heavily dependent on the availability of low-price petroleum as a feedstock. Recent life-cycle analyses suggest that pursuing both strategies of renewable energy sources and renewable feedstocks (i.e. biomass) will be required to meet these competing demands. Reducing the global use of both energy and manufactured chemicals will be a challenge for sustainable development. Education of the next generation of chemists and chemical engineers will have to change significantly from its current emphasis on petrochemical-based manufacturing to include a much greater emphasis on renewable resources and bio-based processes.Brief accounts of this work were presented at the 7th International Symposium on Green Chemistry in China (Zhuhai, People’s Republic of China, May 2005) and at the Joint US–China Green Chemistry Workshop (Beijing, People’s Republic of China, May 2005; this workshop was supported by US National Science Foundation grant CHE-0522369).     

Assessment of farmland sediments after flooding in Ubeji Land in Niger Delta of Nigeria

A study was conducted to evaluate ten heavy metals in dry sediment samples used to assess the contamination of farmland in Niger Delta after a protracted flooding. Eighteen sediment samples in six locations were collected. Niger Delta is a major industrial area where Nigeria petrochemical company is located. These sediments were subjected to analysis using standard methods for the examination of the soil samples. Results showed a trend toward induction of environmental contamination with Zn, Cu, Fe, Hg and Pb on the farmland. Mercury and Lead are disproportionately higher than other sediment elements. Concentrations of these sediment elements are above compliance limit for Nigeria and these may have long-term adverse effects on soil and vegetation.     

CO2 emission reduction for Japanese petrochemicals

Energy efficiency in the Japanese industry is one of the highest in the world. As a consequence, reduction of CO₂ emissions is considered to be difficult and costly. However little attention has been paid as of yet to changes related to so-called non-energy use of fossil fuels. The analysis in this paper suggests that a large number of options exist for emission reduction in the Japanese petrochemical industry. This includes the introduction of biomass feedstocks, the introduction of new catalytic production processes, and changes in waste handling. The use of bioplastics and the use of CO₂ feedstocks seem costly options for GHG emission reduction that should not be applied on the short term. Japanese GHG emissions can be reduced by 7.7% if the optimal set of emission mitigation options is applied. About 60 Mt emission reduction (4.9%) can be achieved by changes on the supply side, another 35 Mt emission reduction (2.8%) can be achieved by changes in waste management. While changes in waste management can be implemented before 2010, biomass introduction on the supply side will probably require a longer lead-time. About half of the emission reduction is cost–effective, but will require further technology development. The other half can be achieved at a cost level of 10,000 yen/t CO₂ (80 US$/t CO₂). The latter part is based on proven technology that is currently not cost–effective.     

Carbon accounting for Japanese petrochemicals

This paper discusses two bottom-up models for the estimation of carbon storage and CO₂ emissions related to the nonenergy use of fossil energy carriers. The models show how material flow accounting can be applied to policy making. The nonenergy use emission accounting tables model is a static model, while the chemical industry environmental strategy assessment program (CHEAP) model is a dynamic model of the flows of synthetic organic materials. Both models provide detailed and more accurate estimates of carbon storage in materials than the accounting method that is currently used in the framework of the Intergovernmental Panel on Climatic Change (IPCC) guidelines. The results for both models suggest that carbon storage in synthetic organic materials has been overestimated, and consequently CO₂ emissions have been underestimated. Japanese CO₂ emissions in 1996 were at least 1.9% higher than reported previously. The CHEAP model results indicate that the net carbon storage (storage − emissions in waste incineration) will decrease during the next few decades. This decrease is mainly driven by changing waste management practice. Received: December 8, 2000 / Accepted: August 15, 2001     

Petrochemical markets in the UK: Methodological aspects of assessing future demand

This article focuses on how input-output techniques could be applied to study the petrochemical industry in general and plastics materials in particular. The theory serves as a tool for understanding the operations of the industry and, therefore, allows for a better control and organization of its development process.     

An evaluation of risk assessment framework for industrial accidents in India

Due to rapid industrialization, with high population density and constraints of land, it is expected that level of risks arising from the hazardous industries will increase in India in the coming decades. However, 30 years after the Bhopal accident (1984), except a few discrete regulations, there is as yet no integrated system for assessing and managing risks arising out of these hazardous industries in India. The gravity of aspects related to the management of industrial risk still remains crucially important. In particular, there is no standard guideline on risk analysis methodology, acceptability or tolerability criteria, nor is there an accident database or a risk reduction strategy for the areas where risk levels are already high. On top of this, there are technical and legislative gaps in the institutional framework to implement any of the above mentioned issues. With the backdrop of the Bhopal gas tragedy, the objective of this paper is therefore to evaluate the effectiveness of a comprehensive risk assessment framework for the emerging economy of India, in order to control and/or to reduce the risk level that exists. In this context, regulations and policies pertaining to industrial risk assessment were reviewed.