air pollution compliance testing of a thermal oxidizerair pollution compliance testing of a thermal...
TRANSCRIPT
Bite of Science
Air Pollution Compliance
Testing of a Thermal Oxidizer
FUJIFILM Manufacturing U.S.A., Inc.
David Hine
April 25, 2018
Presentation Outline
My Start and Career as a Chemical
Engineer
How STEM Subjects Impacted My Career
Ideas for STEM Teachers and Students
Details of a Work Project
Application of STEM Knowledge and Soft
Skills to the Project
Fujifilm Manufacturing Facility Greenwood, SC
Fujifilm Manufacturing Facility Greenwood, SC
Printing Plate Factory
RTO Under Testing
Test Point with Sampling Line
Contractor’s Testing Apparatus
Introduction – David Hine
Environmental Engineer / Senior Chemical Engineer
Environmental and Regulatory Compliance Department
FUJIFILM Manufacturing U.S.A., Inc.
Greenwood, SC
BS Chemical Engineering
NC State University, 1980
Work Experience
1980-85 Hercules Inc – Hopewell, VA; Process
Improvement Engineer, Manufacturing Area Supervisor
1985-1987 Hercules Inc – Middletown, DE;
Manufacturing Area Supervisor
1987-1996 Rexham – Matthews, NC; Process Engineer,
Manufacturing Engineer
1996-Present – Fujifilm, Greenwood, SC; Process
Engineer, Technical Manager, Environmental Engineer
The Path to My Career
From childhood wanted to be a “scientist”
Placed in advanced math classes in elementary school
Stayed on the advanced math track in Jr and Sr high
school, taking Calculus in 12th grade and the AP test
Also took Adv Chemistry and Adv Physics in high school
Math + science = engineering
Enrolled in Chemical Engineering at NC State,
Have always enjoyed the chemical plant technical
environment (as compared to management or business).
Important Factors for
Preparation Success – External
Recognition and opportunity by school system for
advanced academic achievement as early as
elementary school and continuing through high school
Motivated by passionate teachers
Strong family unit
Important Factors for
Preparation Success – Internal Personal desire and enjoyment of STEM subjects
Analytical and mechanical
Work ethic
Living through challenges and failures builds a can-do attitude
Independent and having initiative
Curious, optimistic
I’ve had lots of supervisors and above, and tried to emulate
those I admired, and tried not to repeat things l didn’t like in
others.
Self-awareness understanding of strengths and weaknesses.
I wish I had this knowledge much earlier in my career.
STEM Skills and Knowledge
that Helped Me Be Successful Math is very fundamental, and is critical for developing
and determining technical ability.
You may not use calculus in your job, but training the
brain from an early age and learning difficult subjects
and solving complex math problems forms a basis for
having the ability to learn and master other technical
subjects.
Then in the workplace your technically-trained brain will
have the ability to learn, recognize, investigate, and
solve problems of any type, and have the confidence to
persevere.
They don’t pay you to do math problems. They pay you
to handle difficult technical issues.
STEM Skills for Success
One of the best things I learned in high school was in
chemistry where I had to think whether my answer made
logical sense. You didn’t just blindly put down what the
calculator said.
Another key thing I learned was to write things down. In math
it was to show the steps. In chemistry it was to make sure my
units were correct.
In chemistry and physics I learned information that helped me
in the college courses, and which I remember even today.
This included important facts, fun facts, and fundamental
principles of matter and energy. This includes things such as
Base 10, Base 2, etc., two variable algebra, (x-y), graphing,
interpolation/extrapolation, proofs, entropy, enthalpy, pH,
electron orbitals, positive and negative charges of chemical
groups, the periodic table.
Add’l STEM Skills for Success
Having the ability to organize technical information is
important. The use of spreadsheets and embedded
equations is an everyday task.
It is also important to be able to communicate technical
information to others
Oral; written; graphical
Summary form; detailed but logical
To peers, subordinates, and management
Courses and Extracurricular Activities
that Helped Me Be Successful
Summer technical jobs – sense of real-world work
Part-time job – responsibility, manage money
Church – life perspective, balance
Sports – hard work, teamwork, health, de-stress
Advice for Students to Prepare for
the Workforce (the ‘Real World’)
College is the opportunity to have an interim step
between high school and a career. You have to go to
class, do your homework, get along with new people,
and realize that while the professors want you to
succeed and will help if asked, they will let you fail if you
choose not to try and work hard.
But you still have your parents to back you both
emotionally and financially.
It should be a fun time with activities and new friends,
but all things must be in balance.
Advice for a Successful Career
Know your technical information, and plan to always learn
more.
Take initiative, offer ideas, think critically (why and how). Your
boss does not want to have to tell you what to do all the time.
Don’t just report problems. Give at least one idea for solving
the problem.
Get along with people. You’re now a professional and will
need to interface with those who may make you upset without
letting them negatively affect your performance.
Help others. You’ll want and need help as well.
Don’t complain. Everyone has problems and yours aren’t
special, and no one likes a negative person, especially your
boss.
Application Project
Air Pollution Compliance Testing of a
Thermal Oxidizer
Fujifilm’s RTO
RTO Internal Depiction
Background
Chemical companies must dispose of all chemicals in a legal
and environmentally safe manner.
This includes processed chemicals, unused chemicals, test
material, spills, waste, out-of-date material, and bad batches.
The EPA regulates air pollution through the Clean Air Act, and
covers a wide range of industries and process equipment.
Water and land pollution are covered under other regulations.
Regulated companies must comply with the requirements and
periodically prove compliance. Usually this is done using 3rd
party consultants and contractors using procedures and
protocols approved by the EPA. While the EPA writes the
regulations, the states are delegated for verification and
enforcement (DHEC in SC).
Fujifilm Process
At Fujifilm chemicals are used to make products using
safe and efficient processes. Fujifilm makes a variety of
products, typically applying a liquid coating to a web
substrate which is then dried and packaged.
Chemicals called solvents are used to dissolve other
chemicals to make what is called a coating batch which
is a mixture of many chemicals, each with a separate
purpose for the functionality of the product.
Printing Plate Process
The first step is a surface treatment using inorganic
acids and bases.
The second step is to apply the organic photosensitive
coating and dry it.
As the solvent-based coating is heated and dried, the
VOC’s (volatile organic compounds) are evaporated,
collected, conveyed to and burned in a control device
called an RTO (Regenerative Thermal Oxidizer).
The resulting gases are then discharged to the
atmosphere.
The final step of the manufacturing process is
mechanical cutting and packaging of the printing plates.
Project Steps
Preparation
Running the Test
Results and Approval
Preparation
Know what you have to do and why. This is contained
the plant’s operating permit, which is based on state and
federal regulations.
Know the chemical process and the equipment involved.
In this case it was the coating process of the printing
plate coating line with the removal and destruction of its
solvents by an RTO. Major solvents were included MEK
(methyl ethyl ketone) and methanol.
The basic idea in the preparation phase is to make an
overall plan and then work on the details. This is done by
a combination past experience, advice from others, and
individual investigation.
Regulation 63.5160 Eq.1
“If you are determining the control device destruction or removal efficiency, for
each run, determine the volatile organic matter mass flow rates using Equation
1 of this section:”
Where:
Mf = total organic volatile matter mass flow rate, kg/per hour (h).
Cc = concentration of organic compounds as carbon in the vent gas, as
determined by Method 25 or Method 25A, ppmv, dry basis.
Qsd = volumetric flow rate of gases entering or exiting the control device, as
determined by Method 2, 2A, 2C, 2D, 2F, or 2G, dry standard cubic meters
(dscm)/h.
0.0416 = conversion factor for molar volume, kg-moles per cubic meter
(mol/m3) (@ 293 Kelvin (K) and 760 millimeters of mercury (mmHg)).
Regulation 63.5160 Eq.2
“For each run, determine the control device destruction or removal efficiency,
DRE, using Equation 2 of this section:”
Where:
DRE = organic emissions destruction or removal efficiency of the add-on
control device, percent.
Mfi = organic volatile matter mass flow rate at the inlet to the control device,
kg/h.
Mfo = organic volatile matter mass flow rate at the outlet of the control devi
ce, kg/h.
Preparation – Contractor
Determine the main contractor who will do the physical
work. Past contractors are often re-used, but not
necessarily.
Because of the legal implications, a proven track record
is important which includes their knowledge of the
requirements.
The scope of work must be properly defined so they can
give you an accurate quote of the cost.
An on-site planning meeting with the contractor and key
plant personnel is critical to sharing information, asking
pertinent questions, and assigning tasks.
Contractor Test Proposal
Preparation – Others
Determine other contractors and support personnel. In
this project we had to erect scaffolding for safe access to
sampling points, as well as get multiple 100’ heavy duty
power cords. A lift boom had to be arranged through the
in-house maintenance department.
Source of 460V power had to be identified and available
for the test. I worked with an electrical engineer who
helped with this.
Because DHEC requests to be present, they had to be
notified in advance.
Preparation – Cont’d
In addition, DHEC requires a test proposal that they
must approve in advance. This was written by the
contractor with input from Fujifilm.
In this case, I had to include my reasoning for product
selection for maximum output and provide a process flow
diagram pertaining to the various potential pollution
emission points.
Process Flow Diagram
Preparation – Coordination
Because the requirement is to be running the worst-case
product, the timing must be coordinated with the
production planning department, and must be at steady
state conditions for the duration of the test, lasting
approximately ½ day.
The manufacturing department needs to be aware of the
test. And while it should not affect operations the test will
be on production equipment during production of
standard product. The Control Room will be expected to
help with supplying computerized data from the test
period.
Running the Test
The task the day of the test is to make sure that all the
various pieces of the project are working as planned.
The testing contractors arrived early to set up their
equipment.
The special extension cords and boom lift had to be
ready and in place.
Unfortunately the production line had problems, and the
test was delayed by one day. While the contractors were
able to work the overtime, this added cost and concern.
Running the Test – Cont’d
The representative from DHEC arrived and I gave him a
quick tour of the area, and fortunately he was
comfortable with the setup.
Then when the test was actually running, I had to make
sure that the manufacturing line ran at steady state
conditions for the duration. The requirement is three
segments of one hour each, which demonstrates
performance as well as repeatability.
Differential Pressure Monitoring
Results and Approval
Over the next couple of weeks, the testing contractor
calculated the results and summarized them in a report,
which was forwarded to DHEC.
DHEC reviewed the report and in a few more weeks sent
an approval letter to Fujifilm stating compliance with the
regulation!!
That letter was then filed along with all the supporting
information, for documentation and use for future testing.
Test Result Calculations
Test Result Calculations – Cont’d
Test Results - Net
Application of STEM Knowledge
Chemistry
Math
Physics
Technical Writing
Application of Soft Skills
Listening
Critical Thinking
Professionalism
Teamwork
Communication
Respect for others and for authority
Prioritization of time and tasks
Ethics and legal obligations
STEM Knowledge Utilization
Chemistry was used to understand what chemicals were involved
and their properties. This was used to prepare the scenario to DHEC
to prove that the product to be run during testing was the maximum
for solvent loading. This meant taking all the chemical recipes and
determining the amounts used.
Fundamental was to know which were VOC’s and the chemical
reaction for oxidation. For example,
MEK (methyl ethyl ketone):
2CH3COCH2CH3 + 11O2 8CO2 + 8H2O
Methanol:
2CH3OH + 3O2 2CO2 + 4H2O
Ethyl acetate:
CH3COOC2H5 + 5O2 4CO2 + 4H2O
STEM Knowledge Utilization
Math skills are necessary to calculate equations with
multiple variables, typically in spreadsheets.
An understanding of Physics is used as the physical
equipment is combined for the process and testing.
Thermocouples are used to measure high temperatures,
and are a joint of dissimilar metals that generates an
electrical signal proportional to the temperature.
Calculation of air flows is done using pitot tube
measurements and ductwork dimensions.
Soft Skills Utilization
Communication with various people, departments, and companies
Utilization of help from many people
Active listening, written follow-ups to conversations and meetings
Realization of impact if test fails
Budgeting and costs $40K+
DHEC on-site, potential EPA as well
Getting to know DHEC before and after makes it easier to work
through issues that may arise
Handling process upsets and interruptions
Bonus Advice
Key results are often graphed for visual comprehension.
Important but often overlooked aspects are proper units
and titles for the axes, and name and date by the author.
Documentation of the data parameters for others’ ease
of understanding is important. Units are critical and
should be specified (lb vs. kg, F vs. C, etc.).
Conclusion
My Life – From an early age I was interested in STEM subjects and
was supported by family and school.
It continued over the years and remains ever stronger now.
My Career – I’ve had a wide experience of companies but
essentially in the chemical process engineering field with a growth in
understanding and responsibility.
My Project – I was successful in this important project because I
combined much of my taught knowledge of STEM subjects with
acquired technical skills, and utilized soft skills which were
developed over a lifetime.