In The Spotlight
DoE’s HSE department conducted numerous inspection visits. (Image source: DoE)
The Abu Dhabi Department of Energy (DoE) has successfully completed its Safety in Heat campaign, aimed at ensuring compliance with the summer midday work ban for all companies operating in the energy sector.
This regulation, which prohibits outdoor work under direct sunlight from 12:30 pm to 3:00 pm, was in effect from 15 June to 15 September 2024, enhancing worker safety during the hottest months.
Throughout the campaign, the DoE’s Health, Safety, and Environment (HSE) Department conducted numerous inspection visits to sites in Abu Dhabi and Al Ain.
These inspections focused on educating workers, employers, and supervisors on the importance of adhering to the work ban and implementing best practices to minimise heat stress risks. As part of these efforts, companies were encouraged to provide shaded rest areas, fans, ample water, hydration salts, and essential first-aid equipment.
Engineer Abdul Rahman Al Alawi, Director of the HSE Department, underscored the importance of the campaign, noting that it not only reinforced adherence to safety standards but also highlighted essential measures to protect workers from heat-related illnesses. Al Alawi praised the cooperation from various entities and thanked teams involved in promoting worker safety, recognising the campaign’s role in fostering a safe work environment.
The DoE’s campaign included 2,139 internal workshops and 5,056 awareness sessions, reaching approximately 37,759 workers across the sector. Over 7,276 informational brochures were distributed, while social media platforms, videos, text messages, and emails helped deliver more than 3,800 safety messages, benefiting a total of 40,828 workers. Furthermore, 3,943 inspection visits were carried out, verifying compliance with established safety standards.
Mining is one of the most dangerous occupations.
Nearly one in five (18%) workers have experienced harm at work globally, with nearly half of this going unreported, according to the latest edition of the Lloyd’s Register Foundation World Risk Poll
The research comes from global safety charity Lloyd’s Register Foundation’s latest report: Engineering safer workplaces: Global trends in occupational safety and health using World Risk Poll data collected by global analytics firm Gallup, who conducted 147,000 interviews in 142 countries and territories around the world.
According to the report, rates of harm vary greatly from sector to sector, with fishing named as the most dangerous occupation, just ahead of construction and mining. Low- and lower-middle-income countries were also found to have higher workplace harm rates (19% and 22%, respectively). Almost two thirds of the global workforce (62%) have never received occupational safety and health (OSH) training about risks associated with their work.
Those in less stable forms of employment, such as part-time employees, were found to be more likely to suffer from harm than full-time employees (20% versus 15%). This is compounded by the fact that rates of training were found to be lower for part-time employees – less than a quarter (23%) had received workplace safety training in the past two years, compared to 41% of full-time employees.
Only half (51%) of the workers globally who experienced harm at work say they reported it. The report found that the more recently people have had training, the more likely they are to report workplace harm if they experience it. Individuals who had received workplace safety training in the last two years are 3.3 times more likely to report harm, compared to those who had never received any.
Nancy Hey, director of evidence and insight at Lloyd’s Register Foundation, said, “Low reporting rates, combined with a potential lack of awareness due to low training rates, mean that the true extent of workplace harm is rarely revealed. That’s why safety and health interventions that are both regular and tailored must be a priority for both businesses and policymakers, along with clear reporting tools for all employees – including both part-time and full-time. Special efforts must be made to reach those most at risk and ensure they have a holistic understanding of what safety and health means, as well as an in-depth knowledge of essential procedures in place to keep them safe."
According to International Labour Organization (ILO) estimates, nearly three million people worldwide die of work-related accidents and diseases every year. Another 395 million workers sustain non-fatal injuries, particularly in hazardous industrial sectors such as agriculture and construction.
The report can be downloaded here
The command centre offers essential real-time insights. (Image source: Core42)
The Abu Dhabi Civil Defence Authority, in collaboration with Core42, a G42 company specialising in sovereign cloud, AI infrastructure, and digital services, has unveiled an advanced digital portal aimed at improving fire and life safety standards across the emirate.
The portal allows the Abu Dhabi Civil Defence Authority, building owners, and maintenance companies to register, manage, and update safety protocols in real time. Developed as part of the Hassantuk programme by Core42, the new system enhances safety for residents by reducing property damage and accelerating emergency response times.
This innovative solution not only improves safety but also streamlines operational efficiency for maintenance firms and property owners, enabling them to monitor and maintain safety standards more effectively.
Introduced in 2018 by the Abu Dhabi Civil Defence Authority, the Hassantuk programme requires the installation of fire detection devices and integration with the civil defence electronic system in residential and public buildings. The new digital portal, developed by Core42, strengthens this initiative by connecting buildings directly to a command centre, ensuring faster verification and response to fire incidents.
Establising a command centre
The command centre offers essential real-time insights into fire and life safety performance, enabling operators to identify non-compliant buildings, monitor maintenance companies' performance, and ensure transparency in the fulfilment of maintenance contracts.
This contributes significantly to enhancing community safety. The platform includes features such as real-time fault reporting, automated updates, and preventive maintenance tracking, creating a clear communication channel between building owners, maintenance companies, and Civil Defence. This ensures prompt action to address and prevent any safety issues.
Colonel Dr. Engineer Faisal Hassan Al-Qahtani, acting director of the Civil Protection Department, added, "The Hassantuk program has registered over 35,000 buildings in Abu Dhabi, significantly mitigating fire and life risks. With the new smart solution, we can now access real-time data, detect false alarms, and proactively monitor property maintenance, further enhancing safety in a controlled manner. This underscores Abu Dhabi’s commitment to leading in digital solutions that improve the well-being of its residents.”
"We are proud to deliver this state-of-the-art digital solution to the Abu Dhabi Civil Defence Authority and help advance fire and life safety standards in the Emirate," said Yousef Al Harmoodi, chief business development officer, Core42 and general manager, Hassantuk. “Core42 is committed to advancing the digital ambitions of the UAE. Through this portal and command center, we aim to empower the Civil Defence team to monitor compliance, ensure service-level agreements are met, and track maintenance activities in real time. This collaboration reflects Core42’s commitment to driving the nation's vision forward, and positioning Abu Dhabi as a global leader in smart city initiatives."
The last recorded cases of heat-related illness at EGA were in 2020. (Image source: EGA)
Emirates Global Aluminium (EGA), the UAE's largest industrial company outside the oil and gas sector, has announced achieving zero heat-related illnesses for the third consecutive summer.
Heat-related illnesses pose a significant risk for anyone working outdoors during the UAE's intense summer heat, with the potential to be life-threatening if not addressed promptly. EGA’s industrial operations, which generate additional heat, run continuously throughout the summer, requiring round-the-clock outdoor work.
EGA's 'Beat the Heat' programme, in place for over a decade, is a comprehensive, summer-long initiative designed to combat occupational heat stress. It focuses on raising awareness among employees about the early signs of heat-related illness and empowering them to take proactive measures to prevent its onset.
Stress prevention
EGA’s ‘Beat the Heat’ campaign incorporates several measures to prevent heat-related illnesses, including hydration tests conducted before and during shifts, regular breaks, and cooling showers. The programme also features cooling booths, drinking stations, icemakers, and portable air conditioning units installed throughout the production areas to ensure that both employees and contractors remain cool and comfortable during their work shifts.
Medical personnel from EGA’s on-site centres play an active role in heat stress prevention, working closely with employees and providing immediate treatment to anyone reporting early symptoms of heat stress.
Since 2022, EGA has partnered with US technology firm Kenzen to trial wearable technology that monitors key physiological indicators such as core body temperature and heart rate. This summer, 300 EGA employees used these devices, which provide real-time feedback to both the wearer and EGA’s safety team, allowing for the detection of early heat stress signs before they are physically felt.
The last recorded cases of heat-related illness at EGA were in 2020 when two employees required treatment. Both individuals received intravenous hydration and fully recovered within hours.
Abdulnasser Bin Kalban, CEO of EGA, said, “Our success in completely preventing heat-related illness on our sites for the third year in a row proves that this key hazard for outdoor workers in region can be overcome. Occupational heat stress remains a serious challenge in our region and beyond, and we believe our experience has important lessons for everyone employing people to work outside.”
The construction site at New Murabba. (Image source: New Murabba)
The New Murabba Development Company, a subsidiary of the Public Investment Fund (PIF), has announced significant progress on the creation of its ambitious urban destination.
Excavation at the iconic Mukaab and its surrounding podium sites is now 86% complete, with over 10 million cubic metres of earth moved. This milestone highlights the fast pace of the project and reaffirms the company’s commitment to delivering the world’s largest, modern downtown.
In addition to the sheer scale of the development, the project prioritises worker safety, having logged over 3 million safe work hours to date.
This focus on safety underscores the company's belief that progress and worker well-being must go hand in hand as it builds Riyadh's new downtown.
Around 900 workers work on-site every day.
Managing a large number of workers
“These milestones are a testament to the dedication and skill of our team, and our ambition to build a world-class destination that prioritises both innovation and the well-being of our workforce. We are proud of the progress made at New Murabba, and excited to continue shaping the future of Riyadh”, said Michael Dyke, CEO of New Murabba Development Company.
The recent progress that New Murabba made highlights the team’s effort during the excavation process.
One crucial element of the development is the focus on environmentally friendly methods for managing the excavated materials.
The excavation process required the daily use of approximately 250 excavators and over 400 pieces of equipment to effectively manage the extensive excavation work. This serves to underline the considerable scale and magnitude of the operation.
New Murabba is set to build a temporary bridge, a key infrastructure element that will link the construction site by crossing King Khalid Road.
This bridge will play a vital role in enabling continuous development and preparing for the start of Mukaab piling in the coming months. By reducing approximately 800,000 truck movements on public roads during earthworks, the bridge will have a positive effect on the surrounding infrastructure. With around 900 workers on-site daily, the project is progressing swiftly, bringing the landmark destination closer to completion.
Entries will be evaluated through a comprehensive and impartial judging process. (Image source: RoSPA)
The Royal Society for the Prevention of Accidents (RoSPA) has officially launched its 2025 health and safety awards, with NEBOSH as the headline sponsor.
The awards celebrate organisations and individuals dedicated to improving health, safety, and wellbeing within communities. RoSPA and NEBOSH, both longstanding leaders in safety improvements, are inviting applications from businesses and organisations seeking recognition for their achievements in health and safety.
RoSPA's health and safety awards programme, established in 1956, is the longest-running of its kind in the UK. NEBOSH, founded in 1979, has been a key partner in driving global health and safety advancements alongside RoSPA. Together, they have contributed to saving countless lives and promoting safety best practices across industries.
Judging process
Applications are open to organisations of all sizes, from small enterprises to large corporations. The awards highlight excellence in safety management systems, while the Inspiration Awards recognise outstanding achievements by individuals and teams. RoSPA has partnered with Chas, the UK's leading health and safety accreditation scheme, to simplify the entry process for Chas members.
Entries will be evaluated through a comprehensive and impartial judging process, conducted by experienced occupational health and safety professionals. The main award panel will be chaired by Dee Arp, Chief Quality Officer at NEBOSH.
Rebecca Hickman, CEO at RoSPA, said, “We are delighted to kick off the RoSPA 2025 Awards and honoured to have NEBOSH by our side as headline sponsor. Together, we have a long history of improving the health, safety and wellbeing of our communities and the Awards is the perfect way for us to stand together and make a difference.
“We look forward to reading about the health and safety innovations of organisations and individuals around the world.”
Andy Shenstone, chief executive, NEBOSH said, “Aligned with our new strategy, we’re committed to advancing NEBOSH’s mission through social purpose initiatives that expand our charitable impact in the UK and globally. Collaborating with like-minded organisations is crucial to our success, and as a fellow charity, we’re honoured to support RoSPA’s vital work in preventing harm.”
To enter the 2025 RoSPA Awards, find out more information on the process or to see the extra benefits for RoSPA members see www.rospa.com/awards.
Zahi Daher, manager of international business development for Saudi Arabia. (Image source: NFPA)
The National Fire Protection Association (NFPA) has appointed Zahi Daher as the new manager of international business development for Saudi Arabia.
Joining Dana Kamal, director of international business development for the MENA region, Daher will focus on advancing NFPA initiatives in the Kingdom by promoting fire and life safety standards in line with the country’s rapid development.
Daher brings extensive expertise in fire protection, standards management, and business development, having previously worked at UL Standards & Engagement as the regional standards manager for the Middle East and Northern Africa (MENA). In his prior role, he played a key role in building strategic relationships with government bodies, industry associations, and regulatory entities, driving the adoption of international safety standards throughout the region.
His appointment follows the recent opening of NFPA’s regional office in Riyadh and marks a strategic move to enhance fire, electrical, and life safety efforts as part of the Saudi Building Code.
“Saudi Arabia is undergoing an incredible transformation, and I am honoured to help NFPA play a role as fire and life safety standards are implemented throughout this process, aligned with local risks and hazards,” said Daher, adding that, “I look forward to working with stakeholders across the Kingdom to foster an environment where safety continues to be prioritised at every level.”
The panel highlighted emerging trends affecting the industry. (Image source: Intersec KSA)
Sustainability and fire safety were key topics of discussion at Intersec Saudi Arabia’s Fire Protection and Technology Summit. On the exhibition's opening day, leading experts from the region presented insights on the future of sustainable practices in fire safety.
During the session titled ‘Green Technologies for Fire Prevention and Control: Promoting Sustainable Practices in Fire Safety,’ industry specialists such as Mohammed Al Saeefan, fire protection engineering specialist at Saudi Aramco; Abdulaziz Alkhuder, senior project manager at Rua Al Madinah Holding; Dr Ahmed Al-Ghamdi, VP of health, safety, and environment at International Maritime Industries; and Khalid Al Mandil, deputy fire commissioner at Red Sea Global, discussed the use of non-combustible materials, energy-efficient design, and sustainable fire suppression systems in giga project developments.
The panel, moderated by Hani Adnan Abdel Razeq, director of sustainability at AESG, highlighted emerging trends affecting the industry.
Key insights
Alkhuder noted the growing influence of artificial intelligence (AI) in fire and life safety systems, stating, "The growing prominence of AI is leading to the development of integrated fire and life safety systems, enabling the earlier detection and differentiation of fire-related hazards."
He further added, “Sustainability is also a key focus, with projects showcased today emphasising environmental impact alongside fire and life safety. By combining sustainable practices with advanced safety systems, we can enhance the safety of buildings while positively contributing to environmental and economic goals, ultimately creating safer living spaces for all occupants."
Al-Ghamdi highlighted the importance of balancing AI and human expertise, “AI will be a crucial future trend, especially in identifying system risks and enhancing integration. However, the human element – experience and talent – must be seamlessly integrated. This balance is vital, and once achieved, I believe we have a bright future.”
Al Mandil emphasised the need for sustainability in project design, especially in giga projects, saying, “From a giga project perspective, it is very important for sustainability to be a big part of the design phase. As we all know, designers are pushing the boundaries in terms of the incredible projects they are developing, so sustainability must remain an important part of these developments.”
Al Saeefan also weighed in on the impact of AI, explaining, “Trending this year has undoubtedly been AI and its positive impacts, but we also have to be aware of the unknown. As part of our various digital transformation teams at ARAMCO, strategically teaching your AI system carefully is incredibly important. This creates a great opportunity for all systems to be aligned.”
Riham Sedik, show manager for Intersec Saudi Arabia at Messe Frankfurt Middle East, said, "After an incredibly successful opening day, the scene is set for the remainder of the show, in what will undoubtedly be another two days of groundbreaking insights from some of the most respected experts from the fire, safety, and security industries."
Bilal Al Barmawi, CEO and founder of 1st Arabia Trade Shows & Conferences, added, “We have already welcomed thousands of visitors to this sold-out show and look forward to welcoming many more industry professionals as they tap into the latest knowledge from world-leading experts.”
The DoE has called on all sector participants to commit to the new regulations. (Image source: DoE)
The Department of Energy – Abu Dhabi (DoE) recently convened more than 130 key stakeholders from both government and private sectors to discuss safety, compliance, and the future of the petroleum products industry in light of forthcoming regulatory changes.
The workshop, held under the theme Petroleum Products Safety and Compliance, is part of an ongoing effort to ensure the sector adheres to the highest safety and compliance standards for the well-being of the public.
Dr Saif Saeed Al Qubaisi, Acting Director-General of Regulatory Affairs at DoE, stressed the importance of collaboration between both sectors in fostering growth while maintaining stringent safety protocols.
“Safety is a united effort; it is the collective responsibility of our entire sector,” Al Qubaisi said. “As a regulator, we work with both government and private sectors to create an environment conducive to growth, but never at the risk of safety. Safety is, and always will be, our number one priority.”
He also noted that voluntary compliance with safety standards offers multiple advantages, including safer communities, enhanced operational efficiency, cost savings, and a stronger sector reputation.
The upcoming regulatory changes, set to take effect in Q4, will impact all non-ADNOC petroleum products and gas-related activities in Abu Dhabi. The new rules will specifically focus on gas systems in buildings, as well as the manufacturing, trading, transportation, and storage of petroleum products.
The DoE has called on all sector participants to commit to the new regulations, ensuring the sector’s growth while keeping Abu Dhabi safe.
Understanding and leveraging the benefits of reflexes offers a powerful opportunity to prevent serious injuries. (Image source: SafeStart)
When discussing risk management and workplace safety, Personal Protective Equipment (PPE) is often regarded as the last line of defence. This traditional approach, doesn’t account for the most basic protective measures, especially those involving mechanical or kinetic energy.
The role of reflex actions in preventing incidents is a critical factor which is often overlooked. Understanding and leveraging the benefits of reflexes offers a powerful opportunity to prevent serious injuries and fatalities in the workplace.
The traditional model of safety management follows the hierarchy of controls, which places PPE as the last line of defence, a final measure after other controls have failed. However, in certain cases, PPE functions as an escalation control, protecting workers after an incident has already begun. Seat belts, fall arrest harness and similar gear do not prevent accidents but aim to reduce the severity of injuries once an error has occurred. While PPE plays an important role, reflex actions serve as the true last line of defence and the first line of protection in many scenarios.
The Bowtie Model helps illustrate this by mapping sources of hazardous energy—whether mechanical, chemical, thermal, electrical, or biological—and categorising controls into prevention and mitigation. In most cases (over 90%), mechanical or kinetic energy is the source of serious workplace injuries and fatalities, and as a result reflexes or whether the person will get the benefit of their reflexes becomes a critical factor in terms of the potential severity of the outcome. Outside the controlled work environment, where situations are more unpredictable, reflex actions often determine the difference between a close call or near-miss and a fatality. For instance, a reflexive movement could help a pedestrian avoid being hit by an oncoming vehicle.
Traditional safety practices tend to focus on high-risk activities through rules, procedures, and PPE. However, the majority of serious incidents occur during medium or low-risk tasks. Data from over 400 fatal workplace incident reports shows that 47-71% of these fatalities could have been avoided or lessened had the workers benefited from reflexive responses.
The data also reveals that in over 95% of incidents, the unexpected event that caused the injury stems from the individual themselves. Whether it’s due to rushing, fatigue, frustration, or complacency, human factors play a critical role in workplace safety. Reflexes are key to mitigating incidents in these medium to lower-risk scenarios, where more traditional controls may not be as effective.
The role of reflexes in preventing serious injuries
Reflexes are innate to humans and tested at birth to ensure they function properly. However, whether someone gets the benefit of their reflexes is influenced by human factors such as rushing, frustration, fatigue and complacency, which can cause eyes not on task and mind not on task. If a person’s mind is not on task due to complacency, their reflexes can still help prevent accidents, even if the reflex is a bit slower. But if their eyes are also off task, then they might not get a reflex at all, which can significantly increase the risk of a serious injury or fatality.
External factors like technology can exacerbate the issue. Mobile phones and fast-paced environments condition our brains to experience shorter bursts of focus, leaving us vulnerable to distractions.
This highlights the importance of critical error reduction techniques, such as self-triggering on states like rushing, frustration and fatigue, as individuals can feel and identify these states in the moment and then quickly think about keeping their eyes and mind on task. Complacency, on the other hand, is more passive and harder to detect.
One way to counteract complacency is to build strong safety-related habits, such as maintaining visual awareness before moving hands, feet, body or machinery. These habits ensure that employees will still get the benefit of their reflexes even if their minds are not on task, because they will still be looking at what they are doing.
At an organisational level, addressing human factors is crucial for reducing incident rates. Employers can help by ensuring workers have adequate rest, hydration, and a work environment that minimises unnecessary stress. When examining the Bowtie Model, it becomes clear that human factors like rushing, frustration, fatigue, and complacency need to be considered along with the various forms of hazardous energy as these factors lead to critical errors such as "eyes not on task" and "mind not on task," which can severely impact reflexive responses. By understanding and implementing critical error reduction techniques, organisations and individuals can add an extra layer of protection, leveraging reflexes as both a preventative and mitigation tool in workplace safety.
In conclusion, the role of human factors and reflexes and their significance as the real last line of defence and first line of protection has been largely overlooked in workplace safety. Organisations that focus on enhancing cognitive effectiveness and reflexive responses have a much better chance of preventing serious incidents or reducing their consequences.
To explore the full insights from Larry Wilson and Dr Waddah S Al Hashmi on workplace safety and reflexes, read the complete article at https://ae.safestart.com/article/the-hierarchy-of-controls-and-the-bowtie-model/
The third session at HSE Oman Forum 2021 on 'E-HSE Next Revolution in Oman' engaged our audience with insights on Petroleum Development Oman's IHTIMAM system. Port of Salalah highlighted the use of digitized capture to enhance HSE systems and Esteshraf Foresight talked about the importance of setting realistic compliance targets.
PDO's Nadiya al-Harthy and Arabian Industries Projects' Porchelvan Nadanam discussed the implications of environmental regulations on projects and contractors, as well as the pressing need for tighter competency management
HSE Oman Forum's session on 'Risk Overview' hosted panellists from Oman Drydock Company (ODC), Oman Electricity Transmission Company and Petroleum Development Oman who discussed safety challenges, initiatives to ensure skilled human resources for lifting operations and the 12 Golden Rules (life saving) of ODC.
HSE Oman Forum's first session featured Yokogawa RAP Ltd's excellent insights on digital control of work presented by Mark Breese followed by an engaging panel discussing integration of HSE with business continuity, effective modes of communicating in training and PDO's best practices to achieve highest process safety standards.
The 6th edition of the HSE UAE Forum held on 6-7 April 2021 at Habtoor Grand Resort, Dubai was the first live HSE event in the region after the pandemic lockdown and it concluded to a great response.
We welcomed attendees over two days providing access to thought-provoking presentations, case studies and interactive panel discussions. It was the ideal live opportunity for knowledge sharing and networking at this strategic forum.
The forum served as a platform to realize the UAE’s efforts to prioritize workforce safety, sustainability and best practices post COVID-19 where attendees gained access to information on safety practices, latest technologies and solutions to optimise HSE function in the country.
DoE’s HSE department conducted numerous inspection visits. (Image source: DoE)
The Abu Dhabi Department of Energy (DoE) has successfully completed its Safety in Heat campaign, aimed at ensuring compliance with the summer midday work ban for all companies operating in the energy sector.
This regulation, which prohibits outdoor work under direct sunlight from 12:30 pm to 3:00 pm, was in effect from 15 June to 15 September 2024, enhancing worker safety during the hottest months.
Throughout the campaign, the DoE’s Health, Safety, and Environment (HSE) Department conducted numerous inspection visits to sites in Abu Dhabi and Al Ain.
These inspections focused on educating workers, employers, and supervisors on the importance of adhering to the work ban and implementing best practices to minimise heat stress risks. As part of these efforts, companies were encouraged to provide shaded rest areas, fans, ample water, hydration salts, and essential first-aid equipment.
Engineer Abdul Rahman Al Alawi, Director of the HSE Department, underscored the importance of the campaign, noting that it not only reinforced adherence to safety standards but also highlighted essential measures to protect workers from heat-related illnesses. Al Alawi praised the cooperation from various entities and thanked teams involved in promoting worker safety, recognising the campaign’s role in fostering a safe work environment.
The DoE’s campaign included 2,139 internal workshops and 5,056 awareness sessions, reaching approximately 37,759 workers across the sector. Over 7,276 informational brochures were distributed, while social media platforms, videos, text messages, and emails helped deliver more than 3,800 safety messages, benefiting a total of 40,828 workers. Furthermore, 3,943 inspection visits were carried out, verifying compliance with established safety standards.
Mining is one of the most dangerous occupations.
The last recorded cases of heat-related illness at EGA were in 2020. (Image source: EGA)
The construction site at New Murabba. (Image source: New Murabba)
Entries will be evaluated through a comprehensive and impartial judging process. (Image source: RoSPA)
As a result of the upgrade, production increased and performance was optimised. (Image source: CS Combustion)
CS Combustion Solutions recently enhanced the capacity and efficiency of a sulfuric acid production plant located in Africa’s Copperbelt region, where demand for sulfuric acid is crucial in mining applications such as leaching copper and cobalt
Faced with growing demand, the plant needed to increase production while reducing operational costs and improving reliability. Through targeted improvements, CS increased daily production from 2,200 to 3,000 tons and optimised the plant’s overall performance.
Challenges before optimisation
Prior to the upgrade, the plant faced several challenges, including incomplete combustion, which led to sulfur droplets fouling downstream equipment like the waste heat boiler (WHB) and catalyst beds, increasing system pressure and requiring frequent shutdowns for maintenance. Clogging issues with conventional pressure atomisers resulted in frequent, costly nozzle replacements, while poor droplet atomisation caused hotspots in the refractory lining, increasing wear and reducing reliability.
Key measures implemented
CS Combustion Solutions tackled these issues with the following measures:
1. Ultrasonic atomisation: Replacing pressure atomisers with ultrasonic nozzles reduced droplet size from 400 to 110 µm, which minimised fouling, improved combustion, and protected the refractory lining from localised heat.
2. Swirl bodies: Introducing swirl bodies created rotational motion in the combustion air, enhancing flame formation and leading to more efficient sulfur combustion.
3. VectorWall installation: Replacing the plant’s original baffle walls with a VectorWall improved mixing within the combustion chamber, reduced hotspots, and prevented unreacted sulfur carryover to downstream components.
4. CFD analysis: A Computational Fluid Dynamics (CFD) study simulated and optimized the modifications prior to implementation, ensuring targeted performance improvements.
Results and benefits
With these enhancements, the plant boosted production capacity by 30%, enabling 40 tons of sulfur incineration per hour. The new configuration allows maintenance of sulfur guns without stopping operations, reducing downtime and saving US$160,000 annually by decreasing pressure drop. Additionally, precise ultrasonic atomisation prevented sulfur buildup on the refractory, extending its lifespan.
This case study highlights the importance of innovative combustion technologies and detailed pre-implementation analysis, offering valuable insights for facilities facing similar challenges in optimising sulfuric acid production.
SandTrapXL mitigates solids production. (Image source: Halliburton)
The A1-96/3 well is located around 35 km from the Wafa field. (Image source: Adobe Stock)
The oil and gas industry has emerged as a significant adopter of the technology. (Image source: GlobalData)
The company will supply electrochlorination units for the North Field South project. (Image source: Adobe Stock)
The new uvex phynomic cut glove range is manufactured in Germany using 3D hand ‘formas’ to mimic the contours of the hand. (Image source: uvex)
uvex has announced the launch of new safety eyewear and safety gloves, which it will be showcasing at the Health and Safety Event in Birmingham, UK from 30 April-2 May
There are a diverse range of factors to consider from suspension, soft textile materials, vented or non-vented models, to heat regulation accessories, size and aesthetics. (Image source: MSA Safety)
To improve differentiation, hard hats can be customised with different colours and logos. (Image source: MSA Safety)
The global prescription safety glasses market is forecast to grow to US$1bn by 2031. (Image source: Adobe Stock)
There are a number of factors to consider when selecting a hard hat. (Image source: MSA Safety)
Dubai Electricity and Water Authority (DEWA) organised 61 training courses and awareness sessions on occupational health and safety during the first half of 2024, with the participation of 2,110 male and female employees from various divisions. (Image source: DEWA)
Dubai Electricity and Water Authority (DEWA) conducted 61 training courses and awareness sessions on occupational health and safety in the first half of 2024.
These sessions saw the participation of 2,110 employees from various departments. This initiative is part of DEWA's ongoing efforts to enhance its employees' knowledge and skills in occupational health and safety.
Trainings throughout the year
“We are dedicated to effectively implementing quality, health, safety, and environmental management systems according to the highest international standards. We strive to cultivate a culture of occupational safety and health among all employees, enabling them to keep pace with the latest developments in this field. This is part of our responsibility towards our employees, customers, and the employees of suppliers and contractors who work on DEWA’s projects. Additionally, we are committed to providing our services according to the highest standards of quality, efficiency, availability, and reliability,” said HE Saeed Mohammed Al Tayer, CEO of DEWA.
“We offer the best training and awareness programmes to enhance the safe work environment and raise health and safety standards across all DEWA’s projects and operations. This contributes to achieving employees’ happiness and enhances productivity and quality,” said Dr. Yousef Al Akraf, executive vice president of business support and human resources at DEWA.
In addition to the training courses, DEWA organises many events and awareness activities throughout the year. These include Public Health and Safety Week, Internal Health and Safety Week, Contractor Health and Safety Awareness Day, and other activities and events aimed at improving the health and safety systems of human resources. Employees who complete the training provided by DEWA staff are awarded certificates in occupational health and safety.
Employers have a legal duty to safeguard employees from stress at work. (Image source: Canva)
The programme targets all workers in the construction sector or those whose jobs require scaffold installation and usage. (Image source: SPSA)
The awards will take place in Australia this year. (Image source: Canva)
16 memorandums of understanding and agreements were signed to promote cooperation in occupational safety and health. (Image source: Saudi Ministry of Human Resources and Social Development)
The "State-to-Error Risk Pattern". (Image source: SafeStart)
HSE KSA takes place in September this year. (Image source: SafeStart)
H.E. Bandar I. Alkhorayef, the Minister of Industry and Mineral Resources and H.E. Khalil Ibn Salamah, the Deputy Minister for Industrial Affairs with Dr. Hassan Albalawi, CEO and founder of WakeCap. (Image source: WakeCap)
More than 200 key stakeholders are expected to attend the Forum. (Image source: Alain Charles Publishing)
Dubai Electricity and Water Authority (DEWA) organised 61 training courses and awareness sessions on occupational health and safety during the first half of 2024, with the participation of 2,110 male and female employees from various divisions. (Image source: DEWA)
The awards will take place in Australia this year. (Image source: Canva)
To improve differentiation, hard hats can be customised with different colours and logos. (Image source: MSA Safety)
The global prescription safety glasses market is forecast to grow to US$1bn by 2031. (Image source: Adobe Stock)
The programme targets the needs of the oil and gas industry. (Image source: Adobe Stock)
USA looks to develop HSE practices in Egypt. (Image source: Adobe Stock)
There are a number of factors to consider when selecting a hard hat. (Image source: MSA Safety)
Employers have a legal duty to safeguard employees from stress at work. (Image source: Canva)
There are a diverse range of factors to consider from suspension, soft textile materials, vented or non-vented models, to heat regulation accessories, size and aesthetics. (Image source: MSA Safety)
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As a result of the upgrade, production increased and performance was optimised. (Image source: CS Combustion)
SandTrapXL mitigates solids production. (Image source: Halliburton)
The A1-96/3 well is located around 35 km from the Wafa field. (Image source: Adobe Stock)
DoE’s HSE department conducted numerous inspection visits. (Image source: DoE)
Mining is one of the most dangerous occupations.
The command centre offers essential real-time insights. (Image source: Core42)
The last recorded cases of heat-related illness at EGA were in 2020. (Image source: EGA)
The oil and gas industry has emerged as a significant adopter of the technology. (Image source: GlobalData)
The construction site at New Murabba. (Image source: New Murabba)
Entries will be evaluated through a comprehensive and impartial judging process. (Image source: RoSPA)
Zahi Daher, manager of international business development for Saudi Arabia. (Image source: NFPA)
The panel highlighted emerging trends affecting the industry. (Image source: Intersec KSA)
The DoE has called on all sector participants to commit to the new regulations. (Image source: DoE)
Understanding and leveraging the benefits of reflexes offers a powerful opportunity to prevent serious injuries. (Image source: SafeStart)
Paul Burns, who heads corporate HSSE training at ACWA Power. (Image source: ACWA Power)
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DoE’s HSE department conducted numerous inspection visits. (Image source: DoE)
Mining is one of the most dangerous occupations.
The last recorded cases of heat-related illness at EGA were in 2020. (Image source: EGA)
The construction site at New Murabba. (Image source: New Murabba)
Entries will be evaluated through a comprehensive and impartial judging process. (Image source: RoSPA)
The DoE has called on all sector participants to commit to the new regulations. (Image source: DoE)
Understanding and leveraging the benefits of reflexes offers a powerful opportunity to prevent serious injuries. (Image source: SafeStart)
Paul Burns, who heads corporate HSSE training at ACWA Power. (Image source: ACWA Power)
A new safe HMI (SIL 3) will be introduced, providing an advanced, touch-enabled solution for displaying critical safety information. (Image source: Canva)
EHS software to grow by 6.7% in the next ten years, research shows. (Image source: Canva)
Seadrill will equip its fleet of floating drilling vessels with Oil States' MPD technologies. (Image source: Oil States)
WETEX will be held from 1-3 October this year. (Image source: WETEX)