Category Archives: CounterCurrent

Extractive Metallurgy as Inorganic Chemistry

I am involved in an extractive metallurgy project 1 day per week give or take.  So I have been trying to take apart undesirable minerals in an ore to concentrate the desired metal. It’s called beneficiation- a word introduced by Agricola in his book De Re Metallica published in 1556.  I can’t disclose what the desired metal is.  Suffice it to say that it is rather scarce though not a coinage metal. 

What really amazes me is the disconnect between what many of us think of as the field of inorganic chemistry and the field of extractive metallurgy.  In my training as an organikker, I had never been exposed to extractive metallurgy, nor did I even know what it was.  Turns out that it is a field of applied inorganic chemistry. In this field, a metallurgist is the person who figures out how to extract desired metals from ore.  Nobody seems to call them a chemist, at least to their face. They’re the metallurgist.  No doubt there are exceptions.

Well, that clears things up quite a bit. I feel better getting that off my chest.  I’m sure any wayward metallurgist who happens upon this site has already begun to laugh. Extractive metallurgists do synthetic inorganic chemistry. It’s just that they prefer to keep company with a gangue of engineers and geologists rather than those who don’t work with minerals.  I can relate.

Chemistry jobs

Last fall I was invited to speak to some chemistry students at a local university. Being an industry guy, I was perceived as having some “special” insights into getting a job after college.  While I might have been a successful job hunter when I was less than 40, the odds got much longer after that transition to middle age. More on that in another post.

While I cannot outline the exact path to employment- you really can’t do that- I was able to talk about some of the lesser known jobs that  a chemistry degree will enable.  They are not sexy R&D jobs nor are they upper level executive jobs either. I’m not a pharma guy, thankfully, so my comments do not pertain to that bizarre and brutal world of pharmaceuticals.

The jobs I pointed out are critical to the conduct of manufacturing. They are jobs that one might not necessarily get at the entry level either.

So here are some of the jobs I mentioned.  Environmental health and safety- EH&S. Industry needs people who understand the regulatory situation relating to worker safety and to the environment.  EH&S is also concerned with hazardous waste management.  Expertise in this area is critical to the daily operation of any chemical plant.  This is a good place for an entry level and an experienced chemist to enter because the position typically requires a BS degree and greater than high school knowledge of chemicals and hazards.

Purchasing is an area where a chemist can play an important role in the operation of a plant.  Somebody has to source and buy the chemical raw materials. In general, there is spot buying and contract buying. Spot purchasing offers freedom on the upside but possible instability and higher pricing on the down side.  Purchasing under contract offers a better footing for negotiation and long term stability, but may lock the buyer into minimum volume and a firm price schedule. If demand for your product wavers, being locked into a supply agreement can be a problem if you have agreed to take a set volume.

There are various levels of purchasing positions.  At one end is the purchasing of non-chemical products.  Don’t need a chemist to do this.

On the other end is what is called the supply chain (or procurement) manager. Here is where you need to have a chemist.  This person is charged with assuring that there is an uninterrupted supply of feedstocks to the production facility. They are also tasked with assuring that the vendors meet some basic level of QA/QC and are able to document the whole spectrum of quality assurance. That is, does the vendor have the mechanisms in their business structure to assure not only the flow of product out the door, but also that the process is stable and produces material of the proper quality? Here,  management of change is is very important. A supply chain manager also makes site visits and conducts quality audits of vendors.

Business development and sales is an arena that makes good use of chemists and engineers. The most highly prized type of sales and business development person is the fabled “rainmaker”.  Business development is an activity where a manufacturer makes a connection with a customer who needs some particular material manufactured.  The goal in business development is, not uncommonly, to bring a new product into being.

In the chemical world (outside of pharma) there are commodity chemcials and there are custom and fine chemicals.  Commodity chemicals are those for which there are more than one manufacturer and the difference is mostly in the pricing and availability.  A chemical that is commoditized is one in which the volumes are often high and the margins are thin. Think ethylene, sulfuric acid, BTX, etc.

Commodity chemical producers need sales people too, but their job description is more related to account management and sales. If you dig being a sales rep, go for it.

A business development manager is someone who tries to match technological capability to the needs of the customer for more specialized products. This is teh person who looks at the chemistry and SWAGs a price based on paper chemistry and a spreadsheet.  This is often high pressure work. A bad quote may spell trouble for you. Too high and the customer balks. Too low and you may be faced with the wrong expectations by the customer.  Above all, a good business development person manages expectations.

Quality control/assurance is another position for a chemist. This is for someone who is highly organized and is fond of recordkeeping. This is the world of specifications and certificates of analysis, or certs. The QC person is responsible for making sure the company does what it says it will do in regard to product quality. It is a gatekeeper position and it can be a real hot seat. QA/QC can hold up a shipment or it can prevent the plant from using a raw material. It is a powerful post and those who hold it are not universally loved.

Process safety- what I presently do- is a job description wherein chemists are charged with determining whether or not a process is safe to execute. It is a hybrid job- part synthesis, analysis,and P-chem. It requires quite a bit of imagination in that you have to try to imagine possible failure modes and often obscure ways of testing materials for the potential to release hazardous energy.

Inventory management is central to the operation of any manufacturing unit. It is critical to receive raw materials both physically and in the accounting system. Materials have to be stored in designated locations and have to be staged for use according to a master schedule. While is is less common to find chemists here, I suppose it is possible. Often this position is filled by someone who is familiar with the manufacturing environment.

Related to inventory management is shipping and receiving. In order to load hazardous material onto a truck for transport, one must have training in the regulations pertaining to the transport of hazardous goods. In addition to the regs, there is training in operating in a hazardous environment and emergency response. Again, not a lot of chemists will end up here, but it is a job description in the chemical industry.

Finally, there is the possibility of working as a plant operator. You can find a large variety of people operating in a chemical plant. I know ex-firefighters, ex-military, biologists, farm boys, heavy equipment operators, construction contractors, and people who have worked in chemical plants all their adult lives. It is hard work. You have to work on the plant floor wearing PPE that is often uncomfortable, or perhaps sit at a terminal in a control room monitoring a process train.  But if you like working with your hands on machines and electronics in manufacturing, it may be job for you.

If your desire is to be a captain of industry- a CEO or President, then you should forget lab work and go into business development or sales, or even accounting. Anything related to the accumulation of sales dollars, customer service, plant startup, and deep finance is crucial to someone handing you the keys to the corporation.

Yes, I know that there are a few scientists who have ascended to the top, but they are the exception. You must be fluent with the ways of money and show a record of rainmaking.

The other possibility for a chemist is to join a startup venture. But this is hard to find since most startups are begun with a core group of people who know each other. At some point, however, they will begin to recruit skilled people to fit particular slots. I have no real advice to offer here except that startups are very risky. At some point you may be asked to invest more than just time.

Geysers of Enceladus

My day job requires that I can practice the art of calorimetry with some reasonable extent of expertise, so in that vein I have been cracking open some of my dusty p-chem texts and revisiting basic thermo.

The other day while on an excursion to a bricks and mortar bookstore to pick up some of my favorite periodicals (Kitplanes and Vanity Fair), I happened upon a copy Elements of Chemical Thermodynamics by Leonard K. Nash (1970, Dover, $12.95). Feeling bad for Borders and their current run of poor luck, I bought the book as though it would make some difference.

Figure 2 on p 5 (below) shows a schematic of a ice calorimeter.  An ice calorimeter uses a thermally isolated enclosed space M completely filled with liquid and solid water immersed in an insulated tank of ice and water B. The internal, thermally isolated, working volume of water has two important features- it has a small volume sample container R protruding into it and it has a calibrated small inside-diameter expansion capillary C. 

A sample in container R is in thermal contact with reservoir M.  Heat absorbed in M melts some ice and results in the loss of low density ice and the formation of higher density liquid water. The net volume of the contents then decreases and is registered as a column height change in capillary C.

Given the volume change and knowing the density and heat of fusion of water at 0 C, one can calculate the heat absorbed by the reservoir.

So, what about Saturn’s moon Enceladus? The moon is thought to be covered by water ice with liquid water underneath. It’s reasonable to assume that if some volume of water below the ice transitions to the solid phase then the collective volume for liquid water is decreased resulting in an uptick in pressure.

If this happens, it could provide a mechanism for the geyser phenomenon witnessed by the Cassini probe. The geyers could simply be a result of PV work energized by gravity and radiative cooling of the surface and subsequent thickening of the surface ice into the underlying liquid phase.

I’m sure the boys and girls at Cassini have thought of this, but since I’m not tied into the literature I have not heard anybody express it.

Watson, open the pod bay door please

Now that Watson has mopped up in Jeopardy, can we assume that contestants will finally be able to enjoy their free time doing leisurely activities like strolling through the glade instead of enduring the drudgery of game shows?  Finally, technology has freed humans from the shame and humiliation of standing there under the piercing stare of Alex Trebek. 

IBM’s website states that humans win in this new age battle between John Henry and the steam engine.  Yeah, right. IBM wins. One more thing reduces to a tedious, value added algorithm.

Budget Hand Waving

It is interesting to watch how the various factions of our culture interact on the matter of governmental budgets.  It is though a budget is an end in itself. It is though a budget is the final product of government.  Many apply a puritanical spin on budget and debt concepts. This country produces Cotton Mather characters every generation.

What is important about a budget item is what it does out in the field. OK, elected officials pushed the funding for a particular program or acquisition.  It seems to me that what is of interest is the result of the funding, not the protracted battle for funding.  The headline should be the funded project and the politicians can take their credit in the Congressional Quarterly.

The contrived acrimony over budgets is a battle over abstraction.  People make wild claims as to the market or social imperatives and morality of various magnitudes of spending. Spastic gesticulations and flying spittle get air time on the tube.  But perhaps we should go to the actual object of the budget item and have a look? Who knows what we’ll find?

What the republicans bring to the proceedings is a plan for nothing less than social reconstruction. They plan to wrest control over government so they can kill it.  The Teahadist wing and their antebellum jive appeals to a subset of the electorate more at ease with the Luddite ideals of the John Birch Society than to the social ideals of the 20th century. 

I can’t believe that history will look favorably on the conservatives and their irretrievably antisocial doctrines. People who have benefitted in more ways than they understand from the massive civil infrastructure of the USA now want to stop contributing  to it.

It’s too bad there isn’t a  libertarian confederate homeland for them to go to.  They could spend their days privatizing themselves silly while sitting there in the shade, counting their Krugerrands and sipping Mint Julips. Wait a minute, that sounds pretty relaxing …

I wish I was in the land of cotton, old times there are not forgotten,
Look away, look away, look away, Dixie Land.

Top chemistry professors get the idea

A recent issue of C&EN (the Specialty Chemicals swimsuit issue, Vol 89, number 5) quotes several top research profs on the topic of the present glut of PhD’s.  Seems that these professors profess to actually grasp the job picture for recent and current grads.  Was there a flash of light or was there a visitor in the night who whispered the situation to them?  These folks have been benefitting from cheap, abundant, and enthusiastic labor to propel their research forward for decades and suddenly they claim to be paying attention to the job picture for their alums. Oh please!

In his column, Rudy Baum concludes that it isn’t so much that that we have too many PhD’s, but that we aren’t teaching them what they need to “succeed and benefit society.” 

OK. I can get on board with that. But it begs the question, who is going to teach them what they need to know, whatever that is? A bunch of academics who have spent their careers grooming students to be academics?  Are you kidding me? The status quo is not capable of adjusting curricula to make this change.  It isn’t in their bag of tricks. It is well beyond their experience.

Imagine trying to convince a group of faculty members of anything, much less that their past efforts are now obsolete?  Just imagine that happening. I can’t.

C&EN is the publicity organ of ACS. Imagine the handwringing and chafing that had to happen before these Polyanna’s came to publish such findings? The horror, the horror.

The university/research apparatus in the USA is the principal system within which basic R&D gets done in this country. Resources by way of tax revenues are plowed into the university system to maintain the research effort. Corporations hire the graduates of this system and benefit from their education by way of invention and innovation.

IBM, Dow, GE, GM, etc, didn’t grow wealthy and successful in a vacuum. Their hires, many of which came from the US university/research infrastructure, brought their eduction to bear on the problems of market penetration faced by these companies.

These companies took advantage of the entire spectrum of American infrastructure available to them. They did not have to build roads, monitor public health, run power distribution lines, build hydroelectric dams, or fight wars on foreign soil themselves. That infrastructure was provided to them. Yet, these and other corporations are unhappy with operations in the USA and, rather than inventing a domestic solution, are happy to export their operations and magic.

Over time, university departments and institutions grow based on state and federal funding. Now, the system finds itself possibly with excess capacity. But who is going to admit it? Who is going to go along with American industry and admit that R&D is too expensive to do in the USA?

Part of the problem with the present dearth of scientific jobs is with the structure and imperatives of the publically owned corporation. Publically owned corporations are owned by absentee landlords. The owners, i.e., we who have 401(k)’s, are only interested in quarterly growth. Absentee landlords don’t want to throw cash at a new roof and an upgraded sewer line. They (we) insist on rapid growth in shareholder value. That imperative isn’t necessarily compatible with the organic growth of a business or a market. So, if outsourcing of R&D offshore will save money, then the CEO better do it. I think we need a new business model that isn’t so anxious to export our magic.

My libertarian friends will say that this is the natural result of market forces, as though whatever the market wants is good by definition. 

The market is like a stomach. It has no brain. It only wants one thing- more.

Is that automatically the only acceptable consequence? I don’t think so. We have civilization to buffer us from the extremes of reality. Those who advocate adherence to pure market logic are missing the point of civilization.

February Linkkenfest

Did you hear about the polar bear that swam 426 miles? The polar bear and yearling cub swam from near Barrow, Alaska, across the Beaufort Sea to the coast in Canada. The bear was equipped with GPS and a temperature sensor. Investigators say the bear lost 100 lbs in the ordeal. The cub did not survive. Apparently there were no ice floes for the bear to crawl onto.

Tropical cyclone Yasi, a Category 5 storm, has slammed into the coast of Australia in Queensland.

Those wacky libertarians.

Why doing a PhD is often a waste of time, by The Economist.

Robert J. Samuelson at the Wilson Quarterly offers a compelling analysis of the Great Recession.

As for greed and dishonesty, their role in the crisis is exaggerated. Of course, greed was widespread on Wall Street and elsewhere. It always is. There was also much mistaken analysis about the worth of mortgages and the complex securities derived from them. But being wrong is not the same as being dishonest, and being greedy is not the same as being criminal. In general, banks and investment banks weren’t universally offloading mortgage securities known to be overvalued. Some of this happened; testimony before the Financial Crisis Inquiry Commission shows that some banks knew (or should have known) about the poor quality of mortgages. But many big financial institutions kept huge volumes of these securities. They, too, were duped—or duped themselves. That’s why there was a crisis. Merrill Lynch, Bear Stearns, and Wachovia, among others, belonged to this group. –Robert J. Samuelson, Wilson Quarterly, Winter 2011.

Cuppa Noodles

Working late in the lab tonight. Listening to Music from the Hearts of Space on NPR. Couldn’t leave for supper so I had to break into my emergency cup-o-noodles for nourishment, such as it is.  Night is a good time to write reports and tumble deep into the dendritic recesses of the internet. Some companies won’t let you in the building after hours. I’m good as long as I don’t unchain the dragon and let her fly around.

Have to purify some inorganic stuff I made. It’s very problematic. The material has a large coefficient of expansion in the solid phase from room temp up to the mp. The solid mass tends to break the container if you’re not careful.  It’s a real pisser to make some moisture sensitive stuff only to have the jar or flask break on warming.  The earth’s atmosphere will have its way with my lovely anhydrous product and deliquesce it into a corrosive hellbroth.  Glovebags are useful, but not always the answer.  Deliquescent powders have a way of contaminating the interior surfaces of a glovebag, making it sticky like a empty bag of honey-baked ham.

I use glovebags from Aldrich and am less than happy with them. The ziplock fastener always fails after just a few uses no matter how gently I use it.  I’m pretty sure the check we send to SAF for the bags always clears the bank and the funds remain negotiable until they need it. 

And speaking of SAF, I have received many bottles of reagents lately that are absent the usual physical properties printed on the label. You know,  like MW, density, etc. And what print there might be is absolutely microscopic. C”mon guys.

Carbonate Fusions

I’ve been reading about extractive metallurgy in my spare time for the last 18 months. Finally I get to try it. The other day I rediscovered the solvent power of molten sodium carbonate. At 1000 C it dissolves porcelain crucibles. Luckily an hour at 1000 C wasn’t enough for a catastrophic failure, just some melt through on the bottom.

Somehow, seeing your reaction vessel glowing yellow-orange (on purpose) is deeply satisfying and awe inspiring.

At these temperatures, the notion of acidic and basic conditions needs to be recalibrated for low temperature chemists like me. Irrespective of the crucible, I did digest my sample and convert it into a yellowish meteorite shaped like a flattened cupcake.

Carbonate fusions are used to release metals from silicate matrices. Molten carbonate hydrolyzes the silicate matrix and renders the resulting mass amenable to attack and dissolution by mineral acids.  Platinum is the preferred crucible material of construction.  I have such a Pt crucible. It’s beautiful.

anti-IYC 2011

So, what does it mean to have an International Year of Chemistry?  What should it properly celebrate or advance?

I think we chemists have a bit of a professional inferiority complex. The physicists have control over astronomy and space science with its endless pageant of high profile activities and imagery. Glamor-boy physicists have numerous programs on cable channels. Any synthetic utterance of Steven Hawking turns into a documentary.  Medical science people are glorified to embarrassing levels for the most slender blips of therapeutic progress.  Begoggled chemists do flash-bang demonstrations for whomever will watch.

Who will love us for the gift of cheap and abundant synthetic goods? Who will love and adore us for our facility with bond making and breaking?  How many times has the product of your long endeavor been little more than a clear, colorless oil or a white crystalline solid?  Besides you, who could boggle at this? Who will stop and take in a lingering look and shake their head in admiration and wonderment?

I think chemists should clam up about what it is that makes our field so endlesslly fascinating.  We should resist the urge to share the wonder with the world. We should be stingy with the insights and the beauty.  Call it “The Craft” and make it a mystery.  Create scarcity and let the world pay a premium for us to divulge our hard won wisdom.  If we want to create a buzz, then why not try to be quiet about it?  The world adores a mystery.