Technical, Environmental, and Economic Analysis Comparing Low-Carbon Industrial Process Heat Options in U.S. Poly(vinyl chloride) and Ethylene Manufacturing Facilities.

Electrification and clean hydrogen are promising low-carbon options for decarbonizing industrial process heat, which is an essential target for reducing sector-wide emissions. However, industrial processes with heat demand vary significantly across industries in terms of temperature requirements, capacities, and equipment, making it challenging to determine applications for low-carbon technologies that are technically and economically feasible. In this analysis, we develop a framework for evaluating life cycle emissions, water use, and cost impacts of electric and clean hydrogen process heat technologies and apply it in several case studies for plastics and petrochemical manufacturing industries in the United States. Our results show that industrial heat pumps could reduce emissions by 12-17% in a typical poly(vinyl chloride) (PVC) facility in certain locations currently, compared to conventional natural gas combustion, and that other electric technologies in PVC and ethylene production could reduce emissions by nearly 90% with a sufficiently decarbonized electric grid. Life cycle water use increases significantly in all low-carbon technology cases. The levelized cost of heat of viable low-carbon technologies ranges from 15 to 100% higher than conventional heating systems, primarily due to energy costs. We discuss results in the context of relevant policies that could be useful to manufacturing facilities and policymakers for aiding the transition to low-carbon process heat technologies.

Analysis of Legacy and Novel Neutral Per- and Polyfluoroalkyl Substances in Soils from an Industrial Manufacturing Facility.

Per- and polyfluoroalkyl substances (PFASs) have been detected in an array of environmental media due to their ubiquitous use in industrial and consumer products as well as potential release from fluorochemical manufacturing facilities. During their manufacture, many fluorotelomer (FT) facilities rely on neutral intermediates in polymer production including the FT-alcohols (FTOHs). These PFAS are known to transform to the terminal acids (perfluoro carboxylic acids; PFCAs) at rates that vary with environmental conditions. In the current study on soils from a FT facility, we employed gas chromatography coupled with conventional- and high-resolution mass spectrometry (GC-MS and GC-HRMS) to investigate the profile of these precursor compounds, the intermediary secondary alcohols (sFTOHs), FT-acrylates (FTAcr), and FT-acetates (FTAce) in soils around the former FT-production facility. Of these precursors, the general trend in detection intensity was [FTOHs] > [sFTOHs] > [FTAcrs], while for the FTOHs, homologue intensities generally were [12:2 FTOH] > [14:2 FTOH] > [16:2 FTOH] > [10:2 FTOH] > [18:2 FTOH] > [20:2 FTOH] > [8:2 FTOH] ∼ [6:2 FTOH]. The corresponding terminal acids were also detected in all soil samples and positively correlated with the precursor concentrations. GC-HRMS confirmed the presence of industrial manufacturing byproducts such as FT-ethers and FT-esters and aided in the tentative identification of previously unreported dimers and other compounds. The application of GC-HRMS to the measurement and identification of precursor PFAS is in its infancy, but the methodologies described here will help refine its use in tentatively identifying these compounds in the environment.

Residential proximity to toxic metal-emitting industrial sites and toenail metal concentrations in a United States-wide prospective cohort.

BACKGROUND: Industrial facilities across the United States (US) release millions of pounds of toxic chemicals, including metals. Exposure to toxic metals has been associated with adverse health outcomes, but there is limited evidence on the association between living near metal-releasing facilities and the body burden of emitted compounds. OBJECTIVE: To investigate the association between residential proximity to toxic metal-emitting industrial facilities and toenail metal concentrations and to evaluate whether associations differed by race. METHODS: In a sample of 1556 non-Hispanic Black (32.5%) and non-Hispanic White (67.5%) women from the Sister Study, we used the US Environmental Protection Agency Toxics Release Inventory to identify metal-emitting facilities within 3, 5, and 10 km of participants' baseline residences. We measured toenail concentrations (µg/g) of arsenic, cadmium, cobalt, chromium, and lead. Using multivariable linear regression, we examined associations between residential proximity to and emissions from metal-emitting facilities and toenail metal concentrations, stratifying by race. We explored modification of race-stratified associations by neighborhood deprivation, using the Area Deprivation Index (ADI). RESULTS: Black participants were more likely to reside within 3 km of chromium-releasing facilities and 5 and 10 km of all observed metal-emitting sites. Living near metal-releasing facilities was not associated with higher toenail metal concentrations overall. Among Black women, higher chromium emissions exposure was associated with higher toenail chromium levels (ßTertile3vs.non-exposed = 2.36 µg/g, 95% CI = 0.63, 4.10). An association with lead was observed among Black women residing in the most deprived areas (≥75th ADI percentile: ß = 3.08 µg/g, 95% CI = 1.46, 4.71). No associations were observed for White participants. CONCLUSIONS: Despite low exposure prevalence, our findings suggest that living near chromium- and lead-releasing facilities, especially at shorter distances, may be associated with higher corresponding toenail metal levels among Black women, particularly those residing in the most disadvantaged areas.

Bacterial community and filamentous population of industrial wastewater treatment plants in Belgium.

The discharge of industrial water requires the removal of its pollutants, where biological wastewater treatment plants (WWTPs) are the most used systems. Biological WWTPs make use of activated sludge (AS), where bacteria are responsible for the removal of pollutants. However, our knowledge of the microbial communities of industrial plants is limited. Understanding the microbial population is essential to provide solutions to industrial problems such as bulking. The aim of this study was to identify at a high taxonomic resolution the bacterial population of 29 industrial WWTPs using 16S rRNA amplicon sequencing. Our results revealed that the main functional groups were dominated by Thauera and Zoogloea within denitrifiers, Dechloromonas in phosphate-accumulating organisms, and Defluviicoccus in glycogen-accumulating organisms. The activated sludge characterization indicated that 59% of the industrial plants suffered from bulking sludge, with DSVI values of up to 448 mL g-1. From the bulking cases, 72% corresponded to filamentous bulking with Thiothrix as the most abundant filament; meanwhile, the other 28% corresponded to viscous bulking sludge in which Zoogloea was the most abundant genus. Furthermore, the bacterial population did not share a core of taxa across all industrial plants. However, 20 genera were present in at least 50% of the plants comprising the general core, including Thauera, Ca. Competibacter, and several undescribed microorganisms. Moreover, statistical analysis revealed that wastewater salinity strongly affected the microbial richness of the industrial plants. The bacterial population across industrial plants differed considerably from each other, resulting in unique microbial communities that are attributed to the specificity of their wastewaters. KEY POINTS: • The general core taxa of industrial plants were mostly made up of undescribed bacterial genera. • Filamentous bacteria constituted on average 4.1% read abundance of the industrial WWTPs. • Viscous bulking remains a significant type of bulking within industrial WWTPs.

[Analysis of symptoms and influencing factors of low back work-related musculoskeletal disorders among workers in a container manufacturing factory].

Objective: To investigate the occurrence of low back work-related musculoskeletal disorders (WMSDs) among workers in a container manufacturing factory, and to explore the influencing factors. Methods: In June 2022, 952 workers from a container factory were selected as the research objects by cluster random sampling. Through questionnaire survey, the incidence of low back WMSDs symptoms among workers in the past one year was collected, and the influencing factors of low back WMSDs were analyzed by logistic regression. Results: The incidence rate of low back WMSDs was 46.7% (445/952). The factors with higher exposure at work were frequent slight bending (77.0%, 733/952), frequent overtime (74.1%, 705/952), and the need to turn around while working (62.3%, 593/952). Multivariate logistic regression analysis showed that age over 40 years old, smoking, drinking, often bending over slightly, sitting for a long time, maintaining a large bending posture for a long time, often working overtime, limited operating space, and there was always a need to complete conflicting things in the container manufacturing factory workers were the risks of increasing the low back WMSDs (OR=1.68, 1.96, 2.47, 1.49, 1.84, 2.11, 1.90, 1.82, 2.00, P<0.05). Standing at work, always friendly colleagues, and always supportive and helpful leaders were protective factors for low back WMSDs (OR=0.60, 0.32, 0.40, P<0.05) . Conclusion: The incidence of low back WMSDs symptoms in container manufacturing workers is high, and work-related factors such as frequent slight bending, long time holding large bending posture and limited operating space are the focus of ergonomic intervention in container manufacturing enterprises.

Variations of the Level, Profile, and Distribution of PFAS around POSF Manufacturing Facilities in China: An Overlooked Source of PFCA.

The occurrence of per- and polyfluoroalkyl substances (PFAS) was investigated inside two manufacturing facilities in China. Levels, profiles, and spatial distribution of the detected PFAS were found to be distinctly site-specific and influenced by the area's historic function, production structure of the plant, downpour-induced accidental pollution, and variations in the adsorption and transport of compounds. Very high concentrations of PFAS [mainly C4 and C8 perfluoroalkyl sulfonic acids (PFSAs)] were found in topsoil and groundwater from both plants, with the highest values of 4.89 × 106 µg/kg dw and 1.10 × 104 µg/L, respectively. Elevated concentrations of perfluoroalkyl carboxylic acids (PFCAs) in this study were attributed to their unintentional formation during the electrochemical fluorination process, which might be an overlooked source of PFCA. PFAS generally showed decreasing trends from shallow layers to the bottom of the soil core and demonstrated some downward migrations at different soil depths with time, and C4-C8 PFAS presented a deeper seepage than their long-chain homologues. Total organic carbon appeared to be more important for PFAS sorption to the topsoil than to the soil core. Workers were at potential risk of exposure to perfluorooctanesulfonic acid via soil at production and storage related sites. This study provides a critical reference for the systematic control of PFAS pollution around manufacturing facilities and a proof for an overlooked source of PFCA.

A SARS-CoV-2 outbreak in a plastics manufacturing plant.

BACKGROUND: A SARS-CoV-2 outbreak with an attack rate of 14.3% was reported at a plastics manufacturing plant in England. METHODS: Between 23rd March and 13th May 2021, the COVID-OUT team undertook a comprehensive outbreak investigation, including environmental assessment, surface sampling, molecular and serological testing, and detailed questionnaires, to identify potential SARS-CoV-2 transmission routes, and workplace- and worker-related risk factors. RESULTS: While ventilation, indicated using real-time CO2 proxy measures, was generally adequate on-site, the technical office with the highest localized attack rate (21.4%) frequently reached peaks in CO2 of 2100ppm. SARS-CoV-2 RNA was found in low levels (Ct ≥35) in surface samples collected across the site. High noise levels (79dB) were recorded in the main production area, and study participants reported having close work contacts (73.1%) and sharing tools (75.5%). Only 20.0% of participants reported using a surgical mask and/or FFP2/FFP3 respirator at least half the time and 71.0% expressed concerns regarding potential pay decreases and/or unemployment due to self-isolation or workplace closure. CONCLUSIONS: The findings reinforce the importance of enhanced infection control measures in manufacturing sectors, including improved ventilation with possible consideration of CO2 monitoring, utilising air cleaning interventions in enclosed environments, and provision of good-quality face masks (i.e., surgical masks or FFP2/FFP3 respirators) especially when social distancing cannot be maintained. Further research on the impacts of job security-related concerns is warranted.

Evaluating the efficacy of hydrogen peroxide vapor against a retroviral vector in a gene therapy manufacturing facility.

An evaluation of the efficacy of 35% hydrogen peroxide vapor (HPV) against a novel Simian Immunodeficiency retrovirus (SIV) was conducted in a 624m3 GMP grade C manufacturing facility. SIV biological indicators, with an average titre of 7.11×108 TU/mL [equivalent to 1.3×108 Reverse transcriptase (RT) nanounits when analysed by F-PERT], were produced on-site using virus presented within an anticipated worst-case support matrix based on the manufacturers commercially confidential virus support media. SIV biological indicators were distributed around the manufacturing facility, including locations identified as key contamination control points by the manufacturer, and exposed to a HPV cycle. Commercially available biological indicators of 6 log10Geobacillus stearothermophilus were co-located with the SIV Biological Indicator (BIs). HPV was found to be efficacious in eliminating the SIV and commercial G. stearothermophilus BIs and offers a simple and robust method for biodecontamination of gene therapy facilities.

Quantitative microbial spoilage risk assessment caused by fungi in sports drinks through multilevel modelling.

The risk of fungal spoilage of sports drinks produced in the beverage industry was assessed using quantitative microbial spoilage risk assessment (QMSRA). The most relevant pathway was the contamination of the bottles during packaging by mould spores in the air. Mould spores' concentration was estimated by longitudinal sampling for 6 years (936 samples) in different production areas and seasons. This data was analysed using a multilevel model that separates the natural variability in spore concentration (as a function of sampling year, season, and area) and the uncertainty of the sampling method. Then, the expected fungal contamination per bottle was estimated by Monte Carlo simulation, considering their settling velocity and the time and exposure area. The product's shelf life was estimated through the inoculation of bottles with mould spores, following the determination of the probability of visual spoilage as a function of storage time at 20 and 30 °C using logistic regression. The Monte Carlo model estimated low expected spore contamination in the product (1.7 × 10-6 CFU/bottle). Nonetheless, the risk of spoilage is still relevant due to the large production volume and because, as observed experimentally, even a single spore has a high spoilage potential. The applicability of the QMSRA during daily production was made possible through the simplification of the model under the hypothesis that no bottle will be contaminated by more than one spore. This simplification allows the calculation of a two-dimensional performance objective that combines the spore concentration in the air and the exposure time, defining "acceptable combinations" according to an acceptable level of spoilage (ALOS; the proportion of spoiled bottles). The implementation of the model at the operational level was done through the representation of the simplified model as a two-dimensional diagram that defines acceptable and unacceptable areas. The innovative methodology employed here for defining and simplifying QMSRA models can be a blueprint for future studies aiming to quantify the risk of spoilage of other beverages with a similar scope.

Automated Micro-Crack Detection within Photovoltaic Manufacturing Facility via Ground Modelling for a Regularized Convolutional Network.

The manufacturing of photovoltaic cells is a complex and intensive process involving the exposure of the cell surface to high temperature differentials and external pressure, which can lead to the development of surface defects, such as micro-cracks. Currently, domain experts manually inspect the cell surface to detect micro-cracks, a process that is subject to human bias, high error rates, fatigue, and labor costs. To overcome the need for domain experts, this research proposes modelling cell surfaces via representative augmentations grounded in production floor conditions. The modelled dataset is then used as input for a custom 'lightweight' convolutional neural network architecture for training a robust, noninvasive classifier, essentially presenting an automated micro-crack detector. In addition to data modelling, the proposed architecture is further regularized using several regularization strategies to enhance performance, achieving an overall F1-score of 85%.

Performance of an aerobic granular sludge membrane filtration in a full-scale industrial plant.

This study quantifies the hydraulic performance of a pilot-scale ultrafiltration system integrated into a full-scale industrial aerobic granular sludge (AGS) plant. The treatment plant consisted of parallel AGS reactors, Bio1 and Bio2, with similar initial granular sludge properties. During the 3-month filtration test, a chemical oxygen demand (COD) overloading episode took place, affecting the settling properties, morphology, and microbial community composition in both reactors. The impact on Bio2 was more severe than on Bio1, with higher maximal sludge volume index values, a complete loss of granulation, and the excessive appearance of filamentous bacteria extending from the flocs. The membrane filtration properties of both sludges, with these different sludge qualities, were compared. The permeability in Bio1 varied between 190.8 ± 23.3 and 158.9 ± 19.2 L·m-2·h-1·bar-1, which was 50% higher than in Bio2 (89.9 ± 5.8 L·m-2·h-1·bar-1). A lab-scale filtration experiment using a flux-step protocol showed a lower fouling rate for Bio1 in comparison with Bio2. The membrane resistance due to pore blocking was three times higher in Bio2 than in Bio1. This study shows the positive impact of granular biomass on the long-term membrane filtration properties and stresses the importance of granular sludge stability during reactor operation.

Noise-induced hearing loss among manufacturing factory workers in Kuching, Sarawak: Prevalence and associated risk factors.

INTRODUCTION: Noise-induced hearing loss (NIHL) is a common problem worldwide. Increased globalisation, as well as industrialisation, gives rise to an increase in the incidence of NIHL worldwide. Malaysia is not spared from this problem, either. The objectives were to determine the prevalence of NIHL and its associated factors among manufacturing factory workers. MATERIAL AND METHODS: A cross-sectional study was done in Kuching, Sarawak, involving 173 randomly selected respondents among manufacturing factory workers. Data collected were respondents' workplace monitoring data and their audiometry records obtained from the factory record, and the otoscopy examinations performed. In addition, respondents were required to fill up an interviewer-guided questionnaire. RESULTS: The prevalence of NIHL was high (49.7%). The factors which were found to have a significant association with NIHL in bivariate analysis were age (p < 0.05, 95% CI), male gender (p < 0.05; OR - 7.60; CI 3.34 -18.38), duration of employment (p <0.05), knowledge of noise level (p < 0.05; OR - 4.11; CI 1.10 - 15.28), working at polishing department (p < 0.05; OR - 4.23; CI 2.13 - 8.43), and smoking (p < 0.05; OR - 39.6; CI 16.5 - 94.8). Pack-years of smoking were also found to have a significant association with p < 0.05. However, only smoking was statistically significant in multivariate analysis, where the risk of developing NIHL was 27.55 (p < 0.005; CI 10.74 - 70.64) among smokers. CONCLUSION: The high prevalence of NIHL despite the existing Hearing Conservation Program (HCP) may indicate that there may be some elements in HCP that require close monitoring by the factory management, and the importance of smoking cessation among the workers exposed to noise at the workplace should be highlighted.

Impact of contracted manufacturing organization protocols on operations in an aca demically based Current Good Manufacturing Practice facility.

Immunotherapy of cancer and other diseases is often dependent on adoptive transfer to patients of cellular products generated in Current Good Manufacturing Practice (cGMP) facilities. With the availability and approval of various cellular products for therapy, cell production facilities are experiencing unprecedented growth in demand for services. Increasingly, these services involve processing of externally generated cells for transfer to the bedside. The arrival of cells from external manufacturing facilities for processing and eventual infusion of cell therapy products into patients creates a new layer of responsibility and adds to an already demanding list of the existing procedures in academic cGMP facilities. Sponsors introduce their own requirements for the handling of cells that the laboratory must incorporate and follow. The challenges of creating additional access to cleanrooms, writing new standard operating procedures, expanding personnel training, altering pre-existing schedules and incorporating additional monitoring for safety of external products alter the balance of laboratory operations. Adjustments for accommodating externally manufactured products are numerous and varied, as each sponsor has requests that are product-specific. If cells produced by several different external manufacturers are handled by the same facility, the negative impact on the regular activities in this facility may be considerable. Here the authors provide a review of operational challenges that an academic-based laboratory faces and discuss solutions that could ameliorate the difficulties related to an increasing volume of industry-sponsored trials. The solution may be the development under the auspices of the Foundation for Accreditation of Cellular Therapy or the Food and Drug Administration of regulations that will guide the processing of products manufactured by external companies and make these regulations broadly applicable in all cGMP facilities.

Tackling the Lead Gremlins: A Response to Take-Home Lead Exposure in a Minnesota Industrial Facility, 2019.

Lead exposure that occurs from contamination inadvertently brought home from a workplace is known as take-home exposure. Take-home exposures are a public health hazard that adversely affects health equity for families and communities. This article describes coordinated action by agencies in Minnesota to curb lead exposure among children of workers at a facility that produces fishing sinkers and battery terminals. (Am J Public Health. 2022;112(S7):S655-S657. https://doi.org/10.2105/AJPH.2022.306982).

Systemic Approaches for Emission Reduction in Industrial Plants Based on Physical Accounting: Example for an Aluminum Smelter.

Greenhouse gas (GHG) accounting in industrial plants usually has multiple purposes, including mandatory reporting, shareholder and stakeholder communication, developing key performance indicators (KPIs), or informing cost-effective mitigation options. Current carbon accounting systems, such as the one required by the European Union Emission Trading Scheme (EU ETS), ignore the system context in which emissions occur. This hampers the identification and evaluation of comprehensive mitigation strategies considering linkages between materials, energy, and emissions. Here, we propose a carbon accounting method based on multilevel material flow analysis (MFA), which aims at addressing this gap. Using a Norwegian primary aluminum production plant as an example, we analyzed the material stocks and flows within this plant for total mass flows of goods as well as substances such as aluminum and carbon. The results show that the MFA-based accounting (i) is more robust than conventional tools due to mass balance consistency and higher granularity, (ii) allows monitoring the performance of the company and defines meaningful KPIs, (iii) can be used as a basis for the EU ETS reporting and linked to internal reporting, (iv) enables the identification and evaluation of systemic solutions and resource efficiency strategies for reducing emissions, and (v) has the potential to save costs.

Relocating Industrial Plants Delivers Win-Win Emission Reduction Benefits to Origin and Destination Regions.

Relocating pollution-intensive factories is one of the most effective measures to meet mandatory environmental regulations in developed cities while simultaneously imposing environmental pressure on the receiving cities. Existing studies often assume that relocated plants produce the same or higher emissions when relocated. However, the current pollution mitigation policies enforce even higher emission standards in the destination after plant relocation. We employ a bottom-up pollution accounting approach to assess the impact of intraregional or interregional relocation of iron and steel plants in China's Beijing-Tianjin-Hebei (BTH) area on various air pollutants; specifically, seven policy scenarios are modeled, based on stringency, implementation scope, and production technologies. We find that relocation combined with emission standards enforcement and shifts from BOF (basic oxygen furnace) to EAF (electric arc furnace) production technology may significantly reduce emissions within and outside BTH areas by as much as 28.8% compared to business as usual. The observed reduction is mainly due to the requirement of meeting ultralow emission standards directly or indirectly after relocation. Both origin and destination cities benefit from the relocation, with limited emission spillovers (+9.1%) for destinations outside BTH and even a net reduction (9.4%) in Tangshan. We conclude that combining factory relocation with stricter emission standards and production technological innovation could circumvent the Pollution Haven Hypothesis and deliver win-win air pollution reduction benefits for both origins and destinations.

Emissions, Isomer-Specific Environmental Behavior, and Transformation of OBS from One Major Fluorochemical Manufacturing Facility in China.

Sodium p-perfluorous nonenoxybenzenesulfonate (OBS), a novel alternative to perfluorooctane sulfonic acid (PFOS), has been widely used in various fields in China and has certain toxic effects similar to PFOS. This study monitored OBS and 15 legacy PFASs in surface water, sediment, soil, and crucian carp near a fluorochemical manufacturing factory (FMF) in Suqian, China, focusing on the emission, isomer-specific environmental fate, and transformation of OBS. One to four orders of magnitude higher concentrations of OBS than other polyfluoroalkyl substances (PFASs) in all samples indicate that industrial emission is an important point source of OBS in the surrounding environment. The concentrations of OBS in surface water, sediment, and soil decreased exponentially as the distance from the FMF increases. The proportions of OBS-c, the dominant isomer, increased in the order: water (75.5 ± 6.4%), sediment (85.7 ± 10%), fish (muscle: 94.1 ± 0.99%; blood: 93.5 ± 1.4%), suggesting its preferential accumulation in sediment and fish than other isomers. Mono-hydroxylated transformation products of OBS were first identified in water, sediment, and fish, suggesting its hydroxylation may exist in the real environment. The transformation of OBS may explain its significantly lower bioaccumulation than PFOS in fish. However, considering the higher BAF of OBS than the regulatory bioaccumulation criterion and the possible stronger toxicity of its transformation products, further studies on its bioaccumulation and transformation are warranted.

End-stage renal disease and metalworking fluid exposure.

OBJECTIVE: Despite increasing prevalence of end-stage renal disease (ESRD), little attention has been directed to how occupational exposures may contribute to risk. Our objective was to investigate the relationship between metalworking fluids (MWF) and ESRD in a cohort of 36 703 male autoworkers. METHODS: We accounted for competing risk of death, using the subdistribution hazard approach to estimate subhazard ratios (sHRs) and 95% CIs in models with cubic splines for cumulative exposure to MWF (straight, soluble or synthetic). RESULTS: Based on 501 ESRD cases and 13 434 deaths, we did not observe an association between MWF and ESRD overall. We observed modest associations between MWF and ESRD classification of glomerulonephritis and diabetic nephropathy. For glomerulonephritis, the 60th percentile of straight MWF was associated with an 18% increased subhazard (sHR=1.18, 95% CI: 0.99 to 1.41). For diabetic nephropathy, the subhazard increased 28% at the 60th percentile of soluble MWF (sHR=1.28, 95% CI: 1.00 to 1.64). Differences by race suggest that black males may have higher disease rates following MWF exposure. CONCLUSIONS: Exposure to straight and soluble MWF may be related to ESRD classification, though this relationship should be further examined.