CATCH Says...

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A new report published in June 2018 shows that UK companies are well-placed to supply valuable materials needed for batteries to be built in UK – a potential £2.7 billion per year business opportunity. The report commissioned by WMG at the University of Warwick, was launched to the Chemical Industry Association at the Chemistry Growth Partnership meeting in London, chaired by Steve Foots, Chief Executive of Croda, and attended by Richard Harrington MP.

The research underpinning the report brought together experts and data from the automotive battery industry and chemicals industry, working in the context of the UK’s Industrial Strategy, points to a large UK battery manufacturing industry opportunity. The report was funded by EPSRC, commissioned and managed by WMG at the University of Warwick acting in their role as the Advanced Propulsion Centre Electrical Energy Storage Spoke, and delivered in partnership with E4tech. WMG’s Professor David Greenwood, one of the report’s authors said:

“This report details a massive opportunity to grow a UK battery chemicals industry and related supply chain. The UK’s Industrial Strategy identified battery development and manufacture as one of the four initial Grand Challenges to coalesce industrial activity upon high growth opportunities. Battery pack manufacturing for electric vehicles (EVs) will logically take place close to the point of vehicle assembly since packs are hard to transport. This in turn implies that the battery cells which make up the packs will best be manufactured in (or close to) the UK. This could also mitigate the loss of vehicle engine production.”

“However for cell production to occur in the UK, the supply chains of chemicals would need to be reconfigured, since most cell production and chemicals supply is currently in Asia. Whilst such components could be imported, to capture the most value cell production and the related chemical and process equipment supply would need to come from UK suppliers.”

The report notes that the UK manufactured 1.7m cars in 2016, around 80% of which were exported (SMMT 2017). Assuming that 50% of the vehicles manufactured in 2030 are electrified vehicles (EVs and PHEVs), and taking into account the expected falls in battery cost, the corresponding value of cell materials per car will be £3,200, worth £2.7bn per year to the UK chemical industry just for UK-built cars, with export potential to Europe of ten times that.

This would see a UK vehicle battery industry requiring these volumes of materials in any one year:

Cell material Annual UK value (£ million) Annual UK volume
Cathode active material 1,040 69,000 t
Anode active material 538 48,000 t
Separator 394 263 million m2
Electrolyte 359 27,000 t
Anode copper foil 215 18,000 t
Electrode binders, solvents and additives 72 10,000 t
Cathode aluminium foil 72 10,000 t

The report makes a range of observations and recommendations that would be key to ensuring that the UK can capitalise on this significant opportunity.

• The battery chemicals supply chain is a highly additional opportunity for the UK chemicals sector. Seizing it will require the automotive battery and chemicals industries to work very closely, guided by the Faraday Challenge.

• UK battery manufacturers find that sourcing process equipment from outside the UK is not a problem but sourcing materials, especially those used for conventional lithium ion batteries, poses supply security issues. UK battery technology developers are currently sourcing their materials from outside the UK and are not facing particular challenges from a supply chain point of view, given the small scales and novel materials

• Conducting joint R&D with technology developers could be a way into the battery supply chain for UK chemical companies, provided they can supply battery-grade materials at scale

• Companies are unclear on exactly what products the battery industry will require, on what scale and when but research such as this can help them plan for a clear future.

• Under current conditions, companies are looking at strategies to enter the battery supply chain that minimise risk, such as adapting existing products, developing new products that can have multiple applications, or conducting R&D activities co-funded by public grants

• Only a few UK companies are already supplying the battery industry at scale. Those who are not will need time, once the business case is made, to develop new products and the necessary production capacity as the typical time to market for new products in the chemical industry is in the order of 2 years

• Many indicated building close partnerships with developers of new battery technology as their preferred strategy, allowing them time to grow and gain competitive advantage over suppliers to current battery technology manufacturers

• Certainty in the UK battery market is essential to enable investment in chemical production plants

• In addition to support for EV adoption and battery manufacturing, perceived risk in the development of the chemicals and process supply chain also needs to be addressed. Support provided should last long enough for the supply chain to reach critical mass

• Supporting the growth of our smaller / SMEs companies could ensure resilience within the UK economy. Funding is required (potentially through Faraday) to engage with these industries to help them de-risk and make the transition into this new sector

The full report can be found here

Note for Editors:

This report was commissioned and supported by the Electrical Energy Storage APC Spoke at WMG, University of Warwick and is the output of a project that combined organisations focused on the automotive battery and chemicals industries in UK. It was funded by EPSRC (The Engineering and Physical Sciences Research Council) and closely supported by the UK Chemistry Growth Partnership and the Knowledge Transfer Network. The consultancy work and this report were executed by E4techThe Centre for Process Innovation provided input and review, especially on UK suppliers of relevant chemicals and processesSixty seven other organisations, listed in the appendix, took part in the interviews and workshop informing this work.

About WMG: WMG is a world leading research and education group and an academic department of the University of Warwick, established by Professor Lord Kumar Bhattacharyya in 1980 in order to reinvigorate UK manufacturing through the application of cutting edge research and effective knowledge transfer.

WMG has pioneered an international model for working with industry, commerce and public sectors and holds a unique position between academia and industry. The Group’s strength is to provide companies with the opportunity to gain a competitive edge by understanding a company’s strategy and working in partnership with them to create, through multidisciplinary research, ground-breaking products, processes and services.

About the APC: The Advanced Propulsion Centre (APC) exists to position the UK as a centre of excellence for low carbon propulsion development and production. The Advanced Propulsion Centre was formed in 2013 and is a £1 billion, ten-year commitment between


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The £15 million BEIS Call for CCUS Innovation will provide grant funding to innovation projects that significantly reduce the cost of capturing and sequestering carbon dioxide (CO2). The scope of the call covers the full range of CCUS innovation which includes carbon capture, transport, utilisation and storage. This covers both power and industrial CCUS and also includes greenhouse gas removal (GGR) approaches that are based on capturing and sequestering carbon dioxide. BEIS is looking to offer grant funding for projects for up to 28 months, finishing before 31st March 2021, and will consider grant applications of up to £5 million for a single project.

UK_CCUS_Call_advert



The Humber hosts a number of energy intensive industries, including: petrochemicals, refineries and alternative fuels production; chemical manufacture and storage; steel making; cement and lime manufacture; glass manufacture; food processing and manufacture; and onshore and offshore gas production and storage.

Although industries are spread across the estuary many businesses are located close to the ports of Hull, Grimsby and Immingham. The figure below shows the interview respondents for this study, which comprise the majority (but not all) of the largest energy users in the region.

The Humber’s ports complex is, with 77m tonnes cargo in 2016 (16% total UK cargo), the UK’s largest for both import of raw materials and components and export of UK manufactured products. It offers excellent access to Europe; with ~30m tonnes annual trade it is the UKs largest port complex trading with the EU.

The region forms one of four major chemicals producing regions in the UK. There are two major chemicals clusters: the Saltend Chemicals Park, and a cluster spread along the South Humber Bank between Immingham and Grimsby, which includes two of the UK’s four oil refineries. Manufacture of renewable fuels and infrastructure represents another key industry in the Humber, notably offshore wind turbine manufacture and servicing, and large UK players in the biofuels industry. Further energy intensive industry in the region includes one of the two UK integrated steel works, a cement works, a lime works and a float glass plant at Goole.

In addition, The Humber is believed to have the largest concentration of food manufacturing research, storage and distribution facilities in Europe, contributing over £1bn to the UK economy. Grimsby is referred to as ‘Europe’s Food Town’, with around 500 food related businesses and a full supply chain of food sector services. Large food manufacturers, are also concentrated around Hull, in addition to major pharmaceutical and personal care product manufacturers.

A summary of the Study can be downloaded here Humber EII Cluster Study – Summary


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Counter Terrorism Policing North East, together with the seven regional police forces, are calling on local communities to help defeat terrorism.

Tuesday, March 20th, saw the launch of the latest national campaign as part of Action Counters Terrorism.  The new head of UK Counter Terrorism Policing has used the launch of a campaign about terrorist attack planning methods to reveal that more than a fifth of reports from the public produce Bntelligence which is helpful to police.

The recently appointed Assistant Commissioner of Specialist Operations (ACSO), Neil Basu, praised the public’s willingness to ACT in response to last year’s unprecedented rise in terrorist activity, which resulted in record numbers of people contacting the police through online referral forms and the confidential hotline to report suspicious behaviour and activity.

Now he is launching the second phase of the ‘ACT -Action Counters Terrorism’ campaign, featuring a new 60-second film based on real life foiled plots, which will show examples of terrorist-related suspicious activity and behaviour, as well as attack planning methodology.

A call to action will encourage the public to report suspicious behaviour and activity via the online tool (gov.uk/ACT), helping the police to prevent terrorism and save lives.

Head of CTP North East, Detective Chief Superintendent Martin Snowden said, “Your assistance is more important than ever.

“The key to tackling the growing threat from terrorism is our (the police) relationship with, and the support of, local communities.

“Any piece of information you may have could be important. Anything you have seen or heard, anything that your instincts tell you isn’t right, please report it. Specially trained officers and staff will take that information and ensure that it is dealt with in the most appropriate way.

“Your decision could help the police prevent terrorism and save lives”

“We have been saying for some time now that communities defeat terrorism, and these figures demonstrate just how important members of the public are in the fight to keep our country safe,” says ACSO Neil Basu.

“Since the beginning of 2017 we have foiled 10 Islamist and four right wing terror plots, and there is no doubt in my mind that would have been impossible to do without relevant information from the public.”

Of the nearly 31000 public reports to Counter Terrorism (CT) Policing during 2017, more than 6600 (21.2%) resulted in useful intelligence – information which is used by UK officers to inform live investigations or help build an intelligence picture of an individual or group.

Research carried out by CT Policing suggests that while more than 80% of people are motivated to report suspicious activity or behaviour, many are unclear exactly what they should be looking for.

The second phase of the ‘ACT -Action Counters Terrorism’ from CT Policing aims to educate the public about terrorist attack planning and reinforce the message that any piece of information, no matter how small, could make the difference between a lethal attack or a successful disruption.

“Like other criminals, terrorists need to plan and that creates opportunities for police and the security services to discover and stop these attacks before they happen” says ACSO Basu.

“But we need your help to exploit these opportunities, so if you see or hear something unusual or suspicious trust your instincts and ACT by reporting it in confidence by phone or online.

“That could be someone buying or storing chemicals, fertilisers or gas cylinders for no obvious reasons, or receiving deliveries for unusual items, it could be someone embracing extremist ideology, or searching for such material online.

“This new film has been made to try and help people understand recent terrorist attack-planning methods, but also to demonstrate that each report from the public can be one vital piece of a much larger picture.

“The important thing for people to remember is that no report is a waste of our time, trust your instincts and tell us if something doesn’t feel right.”

Visit https://act.campaign.gov.uk/ for more campaign details.


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Out on the plant, we have the opportunity to interact with plant personnel, a SCADA system and a real industrial process, which uses water to simulate chemical, pharmaceutical and certain FMCG processes, in a completely benign environment.

We have devised a series of case studies which introduce complex failures, which reduce plant output and raw material yield.

This is the same course we use to train our operations consultants.

GAIN THE CONFIDENCE TO TACKLE PREVIOUSLY UNSOLVED TECHNICAL ISSUES

As pioneered by the aviation industry, the benefit of the simulation over on-the-job training is that we can induce multiple overlaid failures. When things aren’t going to plan, we can stop the simulation, re-brief the team and then re-run the scenario.  This is a paradigm shift in the adult learning experience, in a risk free and enjoyable environment, without the day-to-day distractions of being in the place of work.

You can expect to learn about:

  • Making the complex understandable
  • Spotting patterns in telemetry and output data, so that causal links can be established
  • Direct, independent measurement of critical process parameters, to verify that the operators and computers are telling us the true facts

CATCH PROGRAM

Monday: Afternoon travel to Humberside for evening introduction and a meal at the hotel.

Tuesday: Classroom based introduction to pattern recognition and Fault Tree Modelling. Brief and introduction to the industrial simulator and CATCH staff.

Wednesday: Case study on the industrial simulator on Process Phase 1: Variation in Output. Introduction to case study simulation 2.

Thursday: Case study on the industrial simulator on Process Phase 2: Variation in Yield.  Debrief, close and travel home.

 


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Work has begun to review and update the existing CGP strategy, published in 2013.  Although the overall ambition of the CGP – boosting the gross valued-added contribution of our sector by 50% by 2030 – will not change, the aim to establish the position of the industry represented by CGP in the recently published UK Industrial Strategy. The Strategy will be market led, linking the regions/place, and to key customer sectors such as automotive and life-sciences, and will cover the broad science base represented by the chemistry based industry.  Updating the strategy will also help inform any future sector deal proposals from the CGP.   The updated CGP strategy will be developed in collaboration with key stakeholders, facilitated by CIA (Steve Elliott) and SCI (Sharon Todd) with input from BEIS.

With immediate effect, the following appointments have been made:

  • Harry Swan, Managing Director of Thomas Swan & Co. succeeds Ian Shott as the new Chair of the Innovation theme (now including decarbonisation). SCI will take over management support for the theme and will work closely with Innovate UK and the Knowledge Transfer Network.
  • Richard Carter, Managing Director of BASF UK and Ireland, succeeds Harry as Chair of our Supply Chains theme
  • Paul Booth, Chair of Tees Valley LEP, will lead the new Regions theme, working closely with our regional cluster organisations and with CIA providing management support for the group.
  • Tom Crotty, Director of Ineos; Calum MacLean, Chief Executive of Synthomer and Robert MacLeod, Chief Executive of Johnson Matthey will continue to lead the Energy, Brexit and Skills themes respectively.

The Joint Secretariat for the CGP Leadership Team will continue to be carried out by BEIS and CIA.

For more information please visit http://ukchemistrygrowth.com/Home.aspx



The Humber Environmental Managers Network met on 4 October at CATCH.  The topic for the session was tertiary containment which was led by David Cole.

David commented that if sites have Penstock valves they much check the service records and be sure the systems they have actually work.  David supplied details of the CIRIA C736 guidance

CIRIA C736-Containment systems for the prevention of pollution-s

There is a wider concern that not all sites understand what they need to do when addressing fire water run off.  With the new sentencing guidelines it is vital that large industries look at tertiary pollution risk.  David urges anyone managing a site to read the Bartoline case in law regarding insurance

https://www.out-law.com/page-9300

David can offer detailed Spill Mapping advice and guidance to industry.

David Cole

Technical Director

M: 07769 420634

T: 01299 823158

www.penstocksolutions.co.uk



Our next course will take place next year from 12th to 15th February.  It is carried out in collaboration with CATCH (Centre for the Assessment of Technical Competence) in an authentic, full-scale training factory in Humberside (UK).
The course is run as a three-day intensive and immersive experience. The first day starts with lessons in the training room.  On the second and third day, the training workshop is then taught very practically in a live production environment.  This combination of theoretical teaching in the training room and practical application of Chartwell’s Problem Solving methodology in a factory allows attendees to quickly improve their problem-solving abilities.  They immediately gain their own first-hand experience of problem solving by applying what they have learned to actual processes.

Most of our training and on the job coaching is tailored and delivered on site by our consultants.  Twice a year, we run our Advanced Problem Solving Course in association with HCF CATCH at their training facility in North East Lincolnshire.

 

For further information, please visit http://www.chartwell-consulting.com/en/about/training/

 

 



Industrial sites typically produce physical waste streams and byproducts which are given an appropriate EWC code and description.

Waste companies, including recyclers, composters and biogas facilities etc, can only accept onto their site the materials that meet the EWC codes listed on their site permit.

Footprint Services are now able to provide bespoke reports for your company which display the licenced waste companies which are able to receive the EWC coded wastes that your company produces based on their Environmental Agency Permits.

EWC Report Summary

A bespoke report for your company costs on £200, giving you a full directory of companies relevant to your EWC-classified waste streams (up to 20 EWC codes per company).

For more information or to discuss your requirements, please contact Andrew Gadd at andrew@footprintservices.co or call 07791 304190.


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