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Chemical Industry Digest – April 2022

Local Ammonia Production – Fertilizer made for Local, Social and Environmental Benefits
– Nguyen Van Duc Longa,b, Nam Nghiep Tranb, Jose Osorio- Tejadaa, Volker Hessel
Consider scaled down ammonia production and how it can be made feasible so that fertilisers are made available near to centres of consumption and also addresses supply chain challenges. An out of the box concept.

Do Pre-Commissioning Right 
– Amin Almasi, Consultant
Pre-commissioning is a very important and a vital step before any plant is made ready for the procedure of commissioning. Precommissioning involves step by step inspection, tests, checks and troubleshooting. It also involves addressing any issue that requires immediate attention. A plant’s success depends on correct pre-commissioning with excellent planning, thorough preparation and proper methodologies as outlined in the article.

Process Automation Opens Up 
– Mohan Kalyanaraman, et al. – ExxonMobil Research and Engineering
Digital transformation in the chemical industry is happening at a rapid pace. Today, major chemical companies are collaborating with leading automation process vendors and system integrators to accelerate a revolutionary change in automation through the adoption of open process automation standard procedures. This article explains why an open standard like O-PAS is important.

Out of the Box – Solutions to Industrial Problems
– S Raghava Chari, Independent Consultant
Here Raghava Chari describes the real life plant problems and the innovative solutions one can come up to solve these challenges. This time he explains how carbamate plunger pump problem can be resolved; how a failed flow control valve issue was settled and the solution for a leaky boiler drum level switch.

Chemingineering – Low Hanging Fruit
– K Sahasranaman, Independent Consultant
Methane is responsible for global warming and emission problems across the globe. In the article our columnist emphasizes on the fact that it’s time to adapt new strategies and ideas to cut down on emission. He also mentions that behavioural and dietary habits will go a long way in tackling methane emissions.

Book Review – Life Lessons for Managers
R G Rajan in his maiden book ‘Life Lessons for Managers’ chronicles life’s experiences useful for both upcoming and current managers in industry and business. The importance of good communication, art of listening, attitudes and habits, the importance of learning from one’s failures, leadership qualities and many such personality traits needed for success are presented in an easy to read, storytelling manner.

Industrial Cybersecurity Today

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Abstract
With widespread digitalisation of industry and business, plant wide internet interconnectedness across geographies, external cloud and so on, cybersecurity has become crucially important, and all the more so, in a highly knowledge and know-how based chemical industry. Cyber attacks could come from anywhere: from competitor rivals to countries wanting to steal knowhow or damage to even from terrorists.

This article is therefore very timely and covers in detail the various challenges involved in cybersecurity management. The article is based on key insights shared by cybersecurity experts from a range of industrial companies.

Introduction

Today, most industrial companies have two separate cybersecurity programs. Cybersecurity professionals in the CIO’s organization ensure the security of corporate data, IT assets, networks, and business applications. Technical personnel in operations and engineering take care of the security of OT networks and assets.

Differences in IT and OT technologies, goals, and environments justified the development of separate security programs. However, today’s siloed programs are leaving many plants especially in the chemical and oil and gas industries at risk of a serious cyber incident. OT cybersecurity programs often lack the resources, expertise, and supporting technology to maintain defenses, manage attacks, and secure the new technologies being deployed in operating facilities. CISO efforts to manage security are also being hampered by the lack of OT system visibility and access.

The situation is likely to get worse unless companies act. The industrial cyber threat environment is already becoming more challenging with ransomware, sophisticated attacks like Solar Winds, and the explosion of digital transformation programs. These developments demand proper maintained, end-to-end security of all corporate activities and rapid detection and response to all anomalous events. While most industrial IT security programs have the cyber professionals and advanced security solutions to deal with these new challenges, many OT security programs are still struggling to achieve yesterday’s requirements.

IT/OT cybersecurity convergence offers a cost-effective way to address current and future OT security challenges. IT cyber professionals can fill critical resource and expertise gaps in OT security programs. Common cybersecurity processes can eliminate security gaps between IT and OT systems. Use of similar technologies can enhance visibility and incident response effectiveness.

While convergence offers many benefits, experience shows that combining IT and OT programs can be challenging. Successful convergence efforts have clear convergence goals and proven approaches for addressing critical issues like cultural differences and OT reluctance to use conventional IT security practices and technologies. This article presents some of the lessons learned by leading companies that are already on cybersecurity convergence journeys, with a special slant on the chemical and oil and gassectors.

The Different Goals of IT and OT Teams

Industrial cybersecurity teams face an awesome set of responsibilities and challenges. IT security teams, which are often part of the CIO’s organization, are responsible for managing the security of a wide range of information processing technologies, including workstations, servers, networks, printers, websites, cloud applications, and mobile devices. This includes ensuring the confidentiality of all corporate information and the continuous availability of critical business systems and applications.

OT security teams are commonly assigned to specific facilities and commonly report to plant managers or corporate engineering managers. These people are responsible for ensuring the availability and integrity of control systems, SCADA systems, and a diverse collection of cyber physical systems like robots, packaging systems, etc. Managers expect them to prevent any cyber incidents that might impact safety, product quality, environmental compliance, or operational continuity.

While IT and OT security teams may collaborate on security of interfaces, decisions about OT security within facilities are generally made and funded locally, based on each site’s risk appetite, capabilities, and preferences. IT cybersecurity programs are generally more advanced than those in OT.

The picture is quite different for industrial OT cybersecurity programs. While many sites recognize the need for OT cybersecurity, they rarely invest in more than the basic passive defensive technologies recommended by industry groups. Many also neglect the need to invest in people and solutions to maintain these defenses.

Converging Security Processes

Ransomware and sophisticated attacks have clearly raised top management concern about cyber-attacks. They expect that IT/OT cybersecurity convergence efforts will provide them the visibility and confidence they need to be sure that all cyber risks are being properly managed across all systems and assets. Consistent security metrics, policies, and processes are essential for this goal.

Fig 1. ARC Cybersecurity Model Shows Current State of Industrial Cybersecurity Programs

A common cybersecurity framework provides the foundation for driving consistency across IT and OT cybersecurity efforts. It enables people with significantly different backgrounds to agree on key security issues and the actions needed to address them. An effective framework is comprehensive yet abstract enough to avoid specific implementation details and conflicts about specific security practices and technologies.

Many companies have adopted the NIST Cybersecurity Framework as the overall framework for IT/OT cybersecurity convergence. The completeness of this framework and its general acceptance ensure that all issues are addressed. This framework also provides guidance to specific IT and OT practices, in standards like IEC-62443, NIST 800-XX, and ISO 27000, that can help companies meet the requirements. Some companies have also used the CIS 20 to guide discussions. OT security teams will likely have concerns about the use of IT technologies and practices in OT. But these can be alleviated by ensuring that they are involved in these decisions and can ensure that critical OT constraints are properly considered and respected.

Regardless of the formal reporting structure, converged IT/OT cybersecurity programs generally have a single person who is responsible for cybersecurity. Most often this is the CISO, or the CIO when the CISO is part of the IT organization. This person establishes security policies, monitors compliance, and prepares periodic cybersecurity reports for top management. They may also be charged with setting specific security objectives, managing third-party security agreements, and developing recommendations for new cybersecurity people, processes, and technologies.

Setting an Appropriate Convergence Goal

Many industrial organizations have launched IT/OT cybersecurity convergence programs, but the goals vary significantly. Some want to maintain separate IT and OT cybersecurity programs but improve collaboration in securing system interfaces. Others want to integrate efforts in key areas, like DMZs, where OT uses conventional IT technologies and can support common IT security products and practices. Still others are targeting a complete reorganization of people, processes, and technologies to create a unified corporate cybersecurity program.

Fig 2. A Common Strategy for Converged IT and OT Cybersecurity Teams

These differences reflect the tremendous variations that exist in industrial facilities and digital transformation goals. Some companies have critical operations where a cyber incident could have devastating impacts. Others have simple operations that can tolerate minor OT system disruptions. Some facilities can reap tremendous value from new technologies and OT connectivity, while others see little or no benefits. And many industrial cybersecurity teams need to deal with facilities in all of these categories.

Fig 3. Convergence Goals Should Match the Needs of Individual Sites

Recognizing the benefits of different convergence goals is essential for establishing rational site-specific programs. Building a converged IT/OT cybersecurity program will ultimately involve some changes to security people, processes, and technologies. The willingness of operational managers to support these changes depends upon the costs and benefits that will be generated.

Fig 4. Characteristics of Different Cybersecurity Convergence Goals

Regardless of a program’s goals, there are certain guidelines that should be considered in every IT/OT cybersecurity convergence program:

• IT and OT cybersecurity are equally important. Industrial companies need to protect information, people, and operating assets throughout the corporation to ensure business continuity.

• Convergence is more than just transferring OT security to IT security teams. Conventional IT technologies and practices may work in certain OT system areas, but others will always require people with unique expertise, familiarity, and local access.

• Convergence pace will vary across sites, so convergence plans must anticipate support for sites at different stages of their convergence.

Convergence is Primarily a People Problem

ARC research consistently shows that people represent the biggest challenge for IT/OT cybersecurity convergence programs. Much of this is due to the cultural differences between people who work in office and plant environments. IT and OT security people also have different skills, perspectives on the challenges and approaches to security management.

Building trust between IT and OT personnel is essential but challenging. Successful efforts foster trust through collaborative involvement of both groups in the development of security metrics, standards, policies, and processes. This facilitates effective teamwork through common terminology, shared understanding of risks, and recognition of individual strengths. It also helps to focus everyone’s attention on the issues that represent the highest risks to the organization.

Gaining support from operations and engineering managers is equally important. This requires successful interactions that demonstrate IT respect for plant performance goals. Many companies find that plant engineers are happy to offload responsibility for cybersecurity tasks like patching, once they are confident that cybersecurity professionals won’t create problems for normal system operation.

Retaining cybersecurity resources is another issue that needs to be addressed when planning convergence programs. The general shortage of cybersecurity experts makes it hard to replace these critical people. Managers need to ensure that employees find assignments rewarding and create opportunities for advancement along well-defined career paths. Framing cybersecurity as a separate profession with cross-training opportunities can help in this regard.

Attention must also be given to the role that third parties can play in satisfying resource requirements. This can enable companies to offload some tasks and ensure that permanent employees have the necessary time to focus on critical issues like vulnerability and threat management. Many industrial companies rely upon third parties for security assessments, penetration tests, audits, workshops, and table-top exercises.

End User Perspectives on IT/OT Cybersecurity Convergence

At the ARC Industry 2021 Forum, users from the chemical and oil and gas sectors discussed the people and process challenges of IT/OT cybersecurity convergence. They highlighted the need to move away from the “them vs. us” approach. What works best is combining efforts, talking to each other, and replicating best practices. As systems evolve, it is important to have a cross-fertilization of ideas, experiences, and skillsets to arrive at a single solution – this is the winning way. The entire session can be watched here.

In a second IT/OT cybersecurity convergence session, another set of users discussed the technology challenges. Consensus was that convergence of technologies across IT and OT boundaries gives better outcomes. Securing OT systems and getting the basics right is not easy, they opined. So, instead of reinventing the wheel, proven solutions/techniques can be taken from the IT world and tweaked to suit OT needs. The session can be viewed here.

Recommendations

Many industrial companies are working to converge cybersecurity efforts across business areas and technology domains. Reasons vary but they all see convergence as a way to address a variety of OT cybersecurity challenges including lack of resources, more sophisticated attacks, and digital transformation. ARC research suggests that these benefits can be achieved if companies set appropriate convergence goals and take steps to avoid the major obstacles that can derail their efforts.

ARC has been researching IT/OT cybersecurity convergence for many years and this topic has been the focus of numerous cybersecurity workshops at ARC Forums. The information in this report summarized some of the key insights shared by cybersecurity leaders from a range of industrial companies who have been involved in these discussions. While every company has unique challenges, they will still face similar challenges as they strive to change cybersecurity status quo. Our hope is that this report will help you overcome those challenges.

Based on this and related research, ARC recommends the following actions for owner-operators and other technology users:

• Set realistic goals for your cybersecurity convergence efforts and plan to achieve that goal incrementally using the goals we described as collaboration, integration, and unification. The benefits achieved at each step will garner the support you will need to continue the journey.

• Adopt an overall cybersecurity framework to build your team, identify next steps, and focus your efforts to converge people, processes, and technologies.

• Address people, processes, and technology challenges in that order.

• Consider establishing cybersecurity as a specific discipline within your company. This can ease human resource issues if you choose to develop a single cybersecurity organization.

• Be realistic in your expectations – change takes time. Recognize that every improvement is a step to your ultimate goal of safe and secure operations.

All this and more will be discussed at the 26th Annual ARC Industry Forum from February 14-17, 2022 (physical event, Orlando) and March 7-10, 2022 (online).

BASF and cultsport take comfort to a new level in footwear with Elastopan®

cultsport, a performance wear brand from the house of cult.fit, has launched a collection of running and training shoes with insoles made of BASF’s Elastopan® PU system. When made with Elastopan, the insole is 25% lighter than similar materials yet delivers better shock absorption and up to 50% higher rebound, so consumers experience greater comfort and more power with each stride when wearing the cultsport running and training shoes.

“Our extensive research of the cult.fit fitness community in India shows that the greatest need in performance footwear is comfort and support,” said Puspen Maity, Business Head, cultsport. “Running and training shoes that provide bounce, support, and flexibility enable a comfortable workout or satisfying running session. With BASF’s Elastopan in the insole of the running and training shoes, we have achieved the high level of comfort our consumers in India are looking for in their shoes.”

The materials are easy to process and enables optimal setting time which minimizes wastage.

“Our cooperation with cultsport showcases BASF’s commitment to our customers and how we have the right material to suit their requirements. We are excited to support rising industry trailblazers by bringing their innovative ideas to fruition,” said Minli Zhao, Vice President, Consumer Industry, BASF Performance Materials, Asia Pacific.

Obituary

Dr TSR Prasada Rao – Renowned Catalysis Scientist

(20 January, 1939 – 07 April 2022)

Dr T.S.R. Prasada Rao (Turaga Sundara Rama Prasada Rao), an internationally renowned catalyst scientist and an excellent technocrat passed away on 7th April 2022. His immense contributions in the fields of petroleum refining, petrochemicals, and heterogeneous catalysis are well-known. He was a world-renowned catalysis scientist from India who made outstanding contributions to catalytic science and technology in a career, which spanned over forty years. He worked at Fertilizers Corporation of India (PDIL), Sindri, Indian Petrochemicals Corporation Limited, Baroda and was Director, Indian Institute of Petroleum, Dehradun.

Contributions

His contributions through publications, patents, development of various catalysts and processes and their commercialisation is recognised on various scientific forum. His work on the development of indigenous catalysts for the petrochemical and petroleum industries has benefited India and has placed them at par with contemporary developments elsewhere in the world. Among an impressive and long list of his achievements, xylene isomerization and encelite catalyst commercialisation, commercialisation of mono and bimetallic catalysts for naphtha reforming, commercialisation of n-paraffin dehydrogenation catalyst were particularly noteworthy.

Recognitions

Dr Rao led Indian Petrochemicals to acquire catalyst manufacturing capabilities expanding India’s position in the global catalyst manufacturing industry. Dr Rao received many prestigious awards – was elected a fellow of the Indian National Academy of Engineering, and the Indian Academy of Sciences. He was also a member of the Andhra Pradesh Akademie of Sciences, the Indian Institute of Chemical Engineers, and the New York Academy of Sciences. He also received many prestigious awards like Om Prakash Bhasin Award for Engineering, Petrotech Lifetime Achievement Award in 2004, FICCI Award Technology Award of the Council of Scientific and Industrial Research, Kamal Kumari Memorial, Doon Ratna Award, Chemtech Outstanding Scientist Award, K. G. Naik Gold Medal, etc. Chemical Industry Digest has been fortunate to publish very informative and useful articles from Dr Rao.

Recently, he was awarded the lifetime contribution award in engineering 2020 by Indian National Academy of Engineering. He was one of the founder pillars of the Catalysis Society of India (CSI) and served as the President of CSI from 1992-94 and was CSI secretary for two terms 1984- 1987 and 1988-1989. He represented India at the Council of International Congress on Catalysis. More than anything, he has been a source of inspiration and strength to almost all the activities of Catalysis Society of India.

Enigmatic Personality

In addition to his contributions as a scientist, technologist, and administrator, he has contributed to the cause of science in his capacity as a member of a number of policy-making agencies like Oil Industry Development Board, Governing body of CSIR, Scientific Advisory Committee, Ministry of Petroleum and Natural Gas, etc. to name a few. Dr Prasada Rao had a wide circle of friends and admirers in the research, academic, industrial, social, and cultural fields and it is very easy to understand the secret of his popularity among such a large cross-section of people. His liveliness, subtle charm, and charisma endeared him to one and all without exception. He was a man of very simple habits and was a highly devout person.

Chemingineering – Non-Lithium Batteries

Massive capacities of energy storage are required for accelerated adoption of renewable power. Metal-air batteries made from cheaper and widely available iron, zinc and aluminium are emerging as serious alternatives to lithium-ion batteries. They are safer, environment-friendly and more sustainable.

Batteries are extremely crucial to accomplish our journey towards net-zero. Lithium presently dominates the battery space with a global market value of $ 40 billion. Paradoxically, lithium-ion batteries are fraught with sustainability issues. Extraction of lithium metal and processing it into batteries are energy intensive processes. One third of lithium is mined in arid salt flats of Chile and Argentina using prodigious quantities of water. Lithium-ion batteries also need significant amount of cobalt, which is mined in one of the poorest countries of the world, Democratic Republic of Congo, using unsafe practices and widespread child labour. It is thus important to look at non-lithium battery chemistries if we have to achieve energy transition in a more sustainable manner.

Grid Storage

At present, the focus of battery applications is primarily concentrated on powering Electric Vehicles, where energy density is of utmost importance. But the limelight is gradually swinging towards stationary energy storage. Massive capacities of grid storage are required if renewables have to penetrate deeper into the economy. The energy storage in this application is required not just for few hours, but continuously for several days and weeks to even out the seasonal vagaries of renewable power. Metal-air batteries are emerging as strong contenders for long term grid energy storage. The levelised cost of storage (LCOS), which is the cost of storing each MWh of energy across a project’s lifetime, taking into account all capex and opex expenses, is the best metric for comparing alternative battery technologies. For a 10-hour storage period, The LCOS for zinc-air battery works out to $100/MWh compared to $125/MWh for lithium-ion system. For longer durations of storage, the gap between the LCOS for the 2 systems widens dramatically.

Metal-Air Chemistry

Metal-air batteries use a metal as the anode and air as the cathode. The electrolyte can be of different kinds – aqueous, non-aqueous and solid-state. The battery works by electrochemical reduction of the oxygen in air and corresponding oxidation of the metal. As the metal oxidises, electrons are produced at the anode which are transferred through the battery’s external circuit. Oxygen is transformed to hydroxide ions at the cathode. The hydroxide ions dissolve in the electrolyte. This represents the discharge cycle of the battery. The reverse reaction happens during the charging cycle, when electricity restores the anode’s metallic state. Different metals have been used as anodes including lithium, sodium, magnesium, aluminium, iron and zinc. The last three have created considerable commercial buzz.

Zinc-Air

Historically, the first metal-air battery was a zinc-air battery used in hearing aids as far back as 1932. The earliest zinc-air battery used a highly alkaline electrolyte that caused many corrosion problems and was not easily rechargeable. Material scientists at a German university developed a new electrolyte that contain water-repellent ions which adhere to the cathode. As a result, the water molecules in the electrolyte are kept away from the cathode and only the zinc ions from the anode react with atmospheric oxygen. The development of a rechargeable zinc-air battery has been plagued by dendrite formation on the electrode which results in short circuiting.

A Canadian start-up Zinc8 has solved this problem using a patented process to emerge as the leader in zinc-air battery technology. Zinc8’s battery consists of a generator that uses renewable power to produce charged particles of zinc. These zinc particles are then stored as a suspension in potassium hydroxide solution. When power is required, the alkaline electrolyte bearing charged zinc particles are pumped to a fuel cell where the zinc gets oxidised to generate electricity. The zinc oxide is recycled to the generator. Zinc8 is working in collaboration with New York Power Authority, the largest state utility in the US, to demonstrate the potential of its technology.

Iron – Air

The idea of using iron in a battery goes back in history to Thomas Edison. In 1901, Edison developed a nickel-iron battery as an alternative to the lead acid battery for cars. He even made a deal with Ford Motors to produce a more efficient car using his nickel-iron battery. But by the time Edison could perfect a more refined prototype, fossil fuel powered vehicles had made deep inroads with their ability to travel long distances without the need for refuelling. Edison’s invention fell by the wayside. More than 100 years later, his idea is back in a new avatar. Researchers have junked the expensive nickel in favour of freely available oxygen from atmosphere.

After years of research shrouded in secrecy, Form Energy, a start-up based in Boston, has unveiled its iron-air battery. The battery consists of thousands of tiny iron pellets, which are made to rust by exposing them to air in the discharge mode. As iron rusts, it loses electrons, which are transferred through the battery’s external circuit. During the charging mode, electricity removes the rust and iron oxide is converted back to pristine iron. The company claims it can store energy at one-tenth the cost of lithium ion batteries. This is because of its high energy density, which at 1200 Wh/kg is double that of lithium ion batteries. The lab-scale prototype is planned to be expanded into a 300 MW pilot project next year. The company conservatively estimates that one MW storage would need an acre of land. Form Energy is backed by Bill Gates, Jeff Bezos and Arcelor Mittal.

The most obvious advantage of iron-air battery is the low cost of iron and its widespread availability unlike lithium, nickel or cobalt, which are concentrated in few pockets on earth. The iron-air battery, with its low discharge rate is unlikely to set the EV industry on fire, but could offer a cheaper alternative to store thousands of terawatt hours of power to stabilise the electricity grid. The iron electrodes are robust and can survive more than 10,000 charge-discharge cycles, which translates into service life of 30 years. Availability of a robust and cheap battery would accelerate the growth of renewable power industry, which is so vital for meeting the net zero targets.

Aluminium – Air

Aluminium, which is far more widely available than lithium, has captured the imagination of researchers vying to develop high capacity batteries with ultra-fast charging capability. The trivalent aluminium has a massive advantage over monovalent lithium in that it can exchange three times more electrons. India, endowed with a huge resource of bauxite, is betting big on aluminium. Indian Oil is collaborating with an Israeli start-up to develop aluminium-air battery that may herald a welcome import substitution. Aluminium-air batteries are not rechargeable, and at the end of their life have to be replaced with a new one; the used up battery being sent for recycling. Fortunately, the infrastructure for recycling of aluminium is already well established.

Epilogue

Metal-air batteries have several advantages. They are safer, environment-friendly and offer high energy densities. Metals like iron, zinc and aluminium are widely available at much more affordable costs than lithium. It is only a matter of time before they become the mainstay of large long-term grid energy storage.

Readers’ responses may be sent to:
k.sahasranaman@gmail.com or
chemindigest@gmail.com

Chemical Industry Digest – March 2022

Chemingineering – Non-Lithium Batteries
– K Sahasranaman, Independent Consultant
As the journey to net-zero gathers pace, development of energy storage technologies are also moving ahead and the trend is towards metal-air batteries. Such batteries, when compared to lithium ones, are safer, environment-friendly and more sustainable.

Energy Transition Road Map For India –Road Blocks & Options Before The Government
– N S Venkataraman – Nandini Consultancy Centre
Article covers the energy situation in India comprehensively, along with the various current sources like oil and gas, coal and the newer ones coming up, primarily based on  renewables. The author analyses the entire energy scenario and the feasible options available to the country.

The Many Advantages of Gear Pumps
– Michael Coburn, Geoff VanLeeuwen – Blackmer and PSG
The many advantages of gear pumps are well presented. It’s versality in handling a wide range of fluids makes it a popular choice for industry.

Basic Design and Selection Criteria of Chemical Dosing Systems
– Anuj Rastogi – Fluor Daniel India Private Limited
Chemical dousing systems are very important mainly for accurate delivery of chemicals into the process – which ensures good quality, trouble free production. The basic design parameter, equipment sizing, and selection criteria are well discussed.

Importance of Specialty Oils and Lubricants in Industry
– Dr Daya Shukla – Raj Petro Specialities Pvt Ltd
Oil and lubricants keep the wheels of industry moving, enabling higher productivity,
reduced downtime, and cost-effective operations. Based on specific industries, specific applications and the context, such oils and lubricants have now come of age with a wide range available, as discussed in the article.

Out of the Box – Solutions to Industrial Problems 
– S Raghava Chari, Independent Consultant
Once again Raghava Chari describes the real life plant problems related to pipelines, corrosion, and plunger pumps in ammonia and urea plants that were resolved by him and his team through root cause analysis and applying native wisdom.

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