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.