Placement Report

Edward Hargreaves Environmental Science (BSc)

Table of Contents

1 Company Overview1.1 Solvay

1.2 Warrington Site

2 Roles & Responsibilities2.1 General

2.2 Groundwater Abstraction & In-situ Bioremediation

2.2.1 Overview

2.2.2 Maintenance

2.2.3 Monitoring

2.3 Annual Groundwater Well Sampling

2.3.1 Sampling

2.3.2 Laboratory Analysis

2.3.3 Data Analysis

2.4 Weekly Environmental Report

2.5 Dust Monitoring

2.6 Piezometer Sampling

2.6.1 Sampling

2.6.2 Analysis

2.7 Weekly HSE Meeting

2.8 River Outfall Monitoring

2.9 Site Protection and Monitoring Programme

2.10 Effluent Analysis

2.11 Miscellaneous Tasks

2.11.1 Waste Disposal

2.11.2 Pneumatic Extraction System Installation

3 Personal Development

4 Acknowledgements

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1 Company Overview

1.1 Solvay

Solvay is a Global company founded in 1863 that manufactures a wide variety of chemicals and plastics.

In 2013 Solvay achieved net sales of €12.4 billion and €2.1 billion EBITDA. The company has 111 sites

with a presence in 55 countries employing nearly 30,000 people. Solvay’s products reach a diverse range

of end markets including consumer goods, automotive, energy, environment, construction, agriculture,

electronics and paper.

1.2 Warrington Site

Solvay’s Warrington site is a Top-tier COMAH (Control of Major Accidental Hazards Regulation) site

that manufactures Sodium Percarbonate Monohydrate (PCS) and Hydrogen Peroxide (H2O2). PCS is a

core component in washing powder and H2O2 has a wide variety of applications but is predominantly used

as a bleaching agent in the textile, pulp and paper industries. The Warrington site is the sole producer of

H2O2 in the UK and is one of two sites in the world licensed to sell a veterinary grade of H 2O2 which is

branded as Paramove®. Paramove® is used to treat lice infestation and gill disease in farmed salmon. The

site has an environmental permit issued by the Environment Agency for operation of its H 2O2, PCS &

combustion processes and is certified to ISO 14001 for it’s environmental management system.

2 Roles & Responsibilities

2.1 General Role

The core responsibility of this placement is to support the Health, Safety & Environment Department

through operation of the bioremediation system and monitoring the site’s groundwater. This

responsibility involves roles such as groundwater sampling, maintenance of the in-situ bioremediation

system, river outfall monitoring and carrying out a variety of environmentally associated tasks assigned

by the HSE Specialist. This report briefly describes each of these roles while highlighting the skills

applied and developed throughout the placement.

2

38% Crude H2O2

KNO3

AO Distribution Ring Main

TBM Trench

Pi

Fi Infiltration Well

Auto Air Relief Valve

Pump Status to

DCS

Flow to

DCS

(Typical 10Ltr/hr)

(typical 1.5Ltr/hr)

(typical 4 m3/hr)

O2 release valve

Kick Back line

38% Crude H2O2

KNO3

AO Distribution Ring Main

TBM Trench

Pi

Fi Infiltration Well

Auto Air Relief Valve

Pump Status to

DCS

Flow to

DCS

(Typical 10Ltr/hr)

(typical 1.5Ltr/hr)

(typical 4 m3/hr)

O2 release valve

Kick Back line

2.2 Groundwater Abstraction & In-situ Bioremediation

2.2.1 Overview

The historical discharge of chemicals from operations on the Warrington site has caused a residue of soil

and groundwater contamination. After a programme of site investigations determined the nature and

extent of the contamination, a groundwater remediation scheme was developed. The purpose of this

scheme is to contain and remediate the affected areas through groundwater abstraction and

bioremediation. The bioremediation system illustrated in Figure 1 involves continual dosing of H2O2

containing phosphate and potassium nitrate (KNO3) into 10 infiltration wells situated across the most

contaminated zone. Groundwater is simultaneously abstracted in balance with infiltration in order to

ensure hydraulic containment of the contamination. Hydraulic containment is crucial on this site as it is

located between the River Mersey Estuary and the Manchester Ship Canal. The abstraction water is

discharged to sewer and monitored periodically. The purpose of this form of groundwater remediation is

to accelerate the natural process in which the contamination is broken down by microorganisms. The

H2O2 decomposes in the groundwater releasing oxygen that acts as an electron acceptor in the chemical

reaction involving the breakdown of the contamination by the microbes. Phosphate & KNO3 are vital

3Figure 1: Bioremediation System

nutrient sources for the microorganisms that increases their activity, therefore,

further speeding up the breakdown of the contamination.

2.2.2 Maintenance

Due to the continuous operation of this system, maintenance must be carried out on a regular basis. The

weekly tasks include; flushing infiltration points (figure 1) to clear oxygen build up caused by

decomposing H2O2, adjusting flow rates to maintain the desired infiltration rate, refilling bulk chemical

storage tanks, manually maintaining dosing & extraction pumps and coordinating with Solvay’s

maintenance team to make electrical repairs when necessary.

2.2.3 Monitoring

In order to avoid compromising the effectiveness of the remediation it is necessary to monitor the system

closely on a regular basis. This involves logging flow rates & tank levels necessary for calculating the AO

plot extraction/infiltration balance and the tonnage of treatment chemicals injected into the groundwater.

These calculations are made using Excel spread sheets and resulting figures are then reviewed by the HSE

Specialist.

2.3 Annual Groundwater Well Sampling

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In order to assess the current degree of groundwater contamination and thus the effectiveness of the

remediation it is necessary to sample an array of 188 groundwater wells across the site.

2.3.1 Sampling

The wells are dipped to determine well water elevations, which are used to calculate purge volumes but

also to provide Solvay’s environmental consultant (Geosyntec) with data necessary for assessing the flow

regime of the shallow groundwater. Wells are purged three times their volume to ensure that stagnant well

water is not sampled. Purge times are calculated using the flow rate of the pump and well water

elevations. Parameters such as pH, electrical conductivity, temperature and oxidation redox potential are

monitored during and after purging to ensure that the parameters have stabilized thus confirming that the

well is completely purged. Subsequent to purging, a sample is taken in a PET bottle and stored in a

refrigerator. The groundwater sampling techniques described above are key methods employed in

groundwater monitoring.

2.3.2 Laboratory Analysis

The most crucial parameter analysed on the groundwater samples is total organic carbon (TOC). This

particular parameter is of importance because it is a key indicator of the concentration of the organic

contaminants. The TOC is measured with a Shimadzu carbon analyser, which requires preparation of

sample vials, producing standard test vials and setting up the software’s sample tables appropriately. pH

is measured again in the laboratory with a more accurate in-situ probe and chloride is also measured via a

titrimetric laboratory analysis.

2.3.3 Data Analysis

Once the results of the analysis are obtained, they are logged on a database containing historical data from

1995 to present. Current data is compared to previous years and if results are unexpectedly dissimilar then

re-sampling is considered in discussion with the HSE Specialist. Subsequent to data logging, analysis is

carried out to determine the degree of reduction of the contamination. Averages and trends are calculated

with the aim of determining how effective the remediation is in comparison to previous years and how it

might be improved in the future. This task further developed large data set analysis which is an essential

skill required in the third year dissertation.

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2.4 Weekly Environmental Report

In order to keep site managers informed of their environmental performance, a weekly environmental

report is distributed each week. This report is comprises a range of spread sheets each displaying data

such as TOC of effluent per tonne of production or number of heavy goods vehicle movements during

sensitive hours. It is the responsibility of this role to update these spread sheets and tables ensuring that all

data is present and displayed appropriately. If data is missing or unusual then liaison with the laboratory

is undertaken. The report is distributed to site managers via e-mail and if there are any issues such as

missing data due to the failure of analytical equipment then this must be effectively communicated. The

key skills employed in this task are Excel proficiency and written & verbal communication.

2.5 Dust Monitoring

This task is carried out twice a year in accordance with the site’s Environmental Permit monitoring

requirements. It involves the sampling of 11 monitoring points and requires coordination to ensure that

the appropriate processes/machinery is operating during sampling. Live data feeds from Aspentech

software (Figure 2) are used to determine when machinery is operational. Data is recorded and compared

to historical values, unusual figures are reported to the HSE Specialist.

6Figure 2: AspenTech Live Data Feed

2.6 Piezometer Sampling

2.6.1 Sampling

Another company present onsite called Perstorp utilises Solvay’s array of groundwater abstraction wells

for their water consumption. As they are pumped, the abstraction wells run the risk of causing deeper

saline water to be drawn up into the shallower non-saline groundwater via up-coning. It is a requirement

of Solvay’s abstraction license to carry out quarterly sampling of four piezometer wells (Figure 3) ranging

in depth to ensure that the natural state of the shallow groundwater is not compromised. This role carries

out the sampling of the piezometer wells using similar techniques to the methods employed in the

groundwater sampling. However, due to the great depth of the piezometer wells, a larger pump is used

and purging time is significantly longer. Therefore, more caution is taken to ensure that the wells are fully

purged prior to sampling. This is accomplished through calculations on an Excel spreadsheet.

2.6.2 Analysis

The key parameter considered in the analysis of the piezometer well water is chloride as the purpose of

this exercise is to ensure the production well is not drawing up saline water into the shallow groundwater.

Internal analysis is carried out on the samples for good reference, however, due to the prominence of the

threat to the shallow groundwater; external analysis is also carried out. Therefore samples must be

appropriately prepared and distributed to an external laboratory. This task requires effective coordination

and communication skills to ensure that samples are analysed prior to expiry.

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Figure 3: Piezometer well depths & locations

2.7 Weekly HSE Meeting

It is essential for an environmentally permitted on ISO 14001 certified site to regularly review key

environmental figures. Therefore, a weekly meeting of the HSE Department occurs through which this

role is assigned the task of reporting key figures. These figures include river outfall data, HGV sensitive

movements, bioremediation system operation stats and dust emissions from the PCS plant. This role has

the responsibility of collating and reviewing the data before calculating trends and averages that are

presented in the report and delivered verbally to the attendees of the meeting. It is important to draw

attention to significant or unusual data that may require action. Significant figures that require action

include breaches of consent of parameters on the river outfall or PCS emissions. The fundamental skills

practised through this task include data collation and verbal communication.

2.8 River Outfall Monitoring

It is important to keep a record of environmental figures that is updated

on a regular basis so that it can be monitored by the HSE Specialist and

referred to with ease by management and auditors. This role has the

responsibility of updating this record weekly by collating data from

numerous spread sheets. These figures must be logged and then

reviewed so that any issues or irregularities can be identified and acted

upon. The particular record described in this section is a summation of

key figures related to the river outfall monitoring station (Figure 4). The

river outfall discharges waste water into the river Mersey estuary so

parameters such as pH and TOC are strictly controlled. Breach of

consent for any parameters requires notification to the Environment

Agency within 24 hours of the event. Therefore, review of the data must be carried out on a daily basis.

Any issues are reported immediately to the HSE Specialist so that the EA can be notified.

2.9 Site Protection and Monitoring Programme (SPMP)

A Formal groundwater Site Protection and Monitoring Programme is currently in place as a requirement

of Solvay’s and Perstorp’s Environmental Permits to demonstrate the permitted processes are not

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Figure 4: River Outfall Monitoring Station

polluting the groundwater. This role was assigned with the task of carrying out

groundwater sampling for this programme. Training by Geosyntec, Solvay’s environmental consultant,

was carried out due to the more precise nature of the sampling required for this programme. The sampling

carried out involved using bailers to fill sample bottles to avoid cross contamination between wells and

samples were also taken in a number of different containers each allocated for varying types of analysis.

Each well was allocated a set of analysis depending on the well location in relation to historical

contamination and processes. The samples were distributed to an external laboratory for analysis which

required the completion of chain of custody paperwork. Due to the large number of samples and analysis

parameters, this task demanded time management and coordination.

2.10 Effluent Analysis

The plant’s effluent is discharged to the sewer, which is consented by United Utilities. United Utilities

have limits on a set of parameters of that are monitored daily to avoid breaching consent. However, on

a quarterly basis samples are sent out for more comprehensive analysis. This task involves coordinating

with the Solvay laboratory to make up samples for distribution to an external laboratory test house and

Solvay’s headquarters in Brussels. Samples are allocated a maximum holding times so ensuring that the

samples arrive at the test houses on time is essential. Once the laboratory has provided the results, the

data must be collated and then reviewed by the HSE specialist.

2.11 Miscellaneous Tasks

2.11.1 Waste Disposal

Due to the nature of the processes on site, there is a considerable amount of waste produced, some of

which is Hazardous. The HSE Specialist is primarily responsible for dealing with the site’s waste so this

role is allocated a variety of jobs involving waste disposal. Waste is electronically logged and filed on a

regular basis. It is essential that this is done appropriately because the records are used for billing

purposes and it is a requirement that they are kept for a defined period of time. Manual waste

disposal/sorting/labelling is also carried out by this role, typically when waste storage containers are

being altered or relocated.

2.11.2 Pneumatic Extraction System Installation

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Due to persistent failing of the electric extraction pumps on the AO plot, the

decision was made by the HSE Specialist to replace the electric pumps with

pneumatic ones (Figure 5). The primary reason for doing this is that it puts more

control of the maintenance of the system into the hands of this role, which is not

competent to carry out maintenance on electric pumps. Before the system could be

replaced, however, it was necessary to justify the new system to management.

Therefore, this role undertook cost analysis of the proposed system by developing

spread sheets and charts illustrating the benefits of the pneumatic system.

Charts were created using calculations of the cost estimates of operation and maintenance over a 5 year

period and the cost analysis showed a payback period of just under 2 years. This task required Excel

proficiency and also the ability to mathematically interrelate multiple variables. Subsequent to approval,

this role undertook the manual installation of the system. This involved engineering the design of the

system in discussion with the HSE Specialist and determining all the fittings required. Numerous fittings

for both the compressed air lines and extraction water pipes were required thus one pump was initially set

up and trialled prior to the procurement of the remaining fittings. This task required both planning and

manual installation skills.

3 Personal Development

This placement has been an opportunity of great value in terms of personal development for a student

aspiring to work in the environmental sector. Through the course of the year the varied range of tasks and

responsibilities at hand have required the application of a wide skill set both practical and academic. Not

only has this placement developed skills essential for a career in the environmental sector but also

assisted in the development of a knowledge base in contaminated land and bioremediation. This is of

great value because based on financial data of the top 12 environmental consultancy firms, contaminated

land related services were estimated to account for 41% of their combined annual revenues in the 2011. In 10

Figure 5: Pneumatic Pump

addition to the skills relevant to a career in the environmental sector, this

placement has also developed a more widely applicable professional skills set.

4 Acknowledgements

I would like to acknowledge all members of the Solvay, Warrington staff for welcoming me onsite and

providing a comfortable work environment. I would also like to make a special acknowledgement to my

supervisor John McDonagh for guiding me through a most valuable work experience that will provide me

with the foundations necessary to achieve my career ambitions. I highly recommend any student aspiring

to work in the environmental sector to take on this challenge and apply the skills they have gained

through their studies at University.

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