This April, chemical engineers, process safety professionals, and industry leaders will gather in Dallas, TX, for the 2025 AIChE Spring Meeting and 21st Global Congress on Process Safety (GCPS). As AIChE’s premier event for practicing chemical engineers, the Spring Meeting and GCPS will feature over 200 technical sessions, showcasing advancements and innovations that drive safety and efficiency in the chemical process industries (CPIs).
The Perspectives on Process Safety Around the World (PPSAW) symposium offers a unique platform for global insights into process safety. It brings together experts from different regions at the Global Congress to discuss the challenges and developments shaping process safety in their respective areas, while considering the distinct language, cultural, and regulatory needs of each region. In 2025, this track will feature its inaugural Process Safety in Mining, Minerals, and Metals (MMM) sessions.
Eduardo Francisco, PPSAW Chair, and Christophe Catala, MMM Session Chair, join us to discuss process safety challenges in mining, metals, and minerals, highlighting unique risks and emerging trends, the role of AI in process safety, and the inaugural MMM sessions at the symposium.
The global nature of the Perspectives on Process Safety from Around the World symposium allows for diverse insights. What regional differences or emerging trends in process safety have stood out to you?
The PPSAW symposium highlights key regional differences in process safety, shaped by regulatory environments, industrial maturity, and technological advancements. This year, we have four dedicated streams: Spanish, Portuguese, Chinese, and Mining & Metals.
There are clear distinctions among regions when it comes to regulatory approaches and safety standards. In North America, strong regulatory frameworks like OSHA PSM and EPA RMP drive safety management, with an increasing emphasis on data-driven approaches, AI, and digital twins for predictive analytics. Europe has a risk-based approach through the SEVESO III Directive, with a growing focus on sustainability and decarbonization. In the Asia-Pacific region, rapid industrial growth is pushing efforts to enhance safety culture, with China and India transitioning from compliance-based to risk-based safety models. In the Middle East robust oil and gas safety standards align with API and CCPS practices, and the region is seeing increased investment in automation to reduce human error. Meanwhile, in Latin America, the adoption of U.S. and European-inspired risk-based regulations is taking place, though challenges in economic conditions and enforcement remain.
Across all regions, several common process safety trends are emerging. Digital transformation is playing a key role, with AI, machine learning, and real-time monitoring enhancing predictive maintenance and risk assessment. There's also a shift towards prioritizing human factors and safety culture, moving from compliance-driven approaches to more proactive strategies that focus on training and behavioral science. Sustainability and climate considerations are becoming increasingly integrated into process safety, with a focus on net-zero goals, safer hydrogen handling, and circular economy principles. Additionally, we're seeing changes in the area of resilience and emergency response, as industries address supply factors such as chain disruptions, cybersecurity risks, and climate-related hazards.
This year marks the inaugural Process Safety in Mining, Minerals, and Metals sessions within the symposium. What led to the addition of these sessions, and how do you see them enriching the broader conversation about process safety?
The growing adoption of process safety management in mining and metals led to the creation of dedicated MMM sessions at this year’s symposium. Initially, many companies attempted to directly transfer process safety practices from oil & gas or chemicals, but limitations soon emerged. Process safety professionals in MMM sought to share challenges and develop industry-specific approaches.
A key challenge remains in defining the scope of process safety in MMM. Perspectives vary widely, highlighting the need for industry alignment. With the CCPS MMM Committee's formation and the strong interest in MMM at the 10th Latin American Conference on Process Safety, we saw an opportunity to expand the discussion globally.
We also see a real need for industry-specific adaptations of process safety principles to address mining and metals specifically.
Process safety in mining, minerals, and metals faces unique challenges compared to traditional chemical processing. What specific safety concerns in these industries are most critical, and how do they differ from those in chemical plants?
While the fundamentals of process safety in MMM share similarities with chemical processing, there are key differences that set it apart. MMM sites have varied risk profiles due to differences in process technologies and risk exposures, making safety management more complex. The presence of molten materials poses unique hazards, as contact with water can trigger devastating explosions, requiring specialized controls. Additionally, unlike the highly automated oil and gas industry, MMM operations rely heavily on human intervention, which makes administrative controls critical. There is also ongoing debate within the industry about the scope of process safety, with questions regarding whether tailings, conveyors, and underground mining should be included. Despite these differences, adopting risk-based safety management, critical control methodologies, and insights from other industries can greatly improve safety outcomes in MMM.
Given that process safety knowledge has traditionally focused on the chemical and oil & gas industries, how can lessons learned in these areas be applied to other industries, such as mining and metals?
Many process safety principles from oil & gas and chemicals—such as risk assessment frameworks, human factors, and technological innovations—are applicable to MMM. However, direct adoption is not always feasible due to differences in equipment, process variability, and reliance on human controls. The key is adaptation rather than direct transfer.
For example, while the concept of inherent safety applies universally, the methods for implementation differ. In oil & gas, inherently safer design often involves material substitution; in MMM, it may involve redesigning smelting operations to mitigate molten material hazards. Similarly, safety barriers in oil & gas are often automated, whereas MMM must emphasize training and procedural compliance due to human-involved operations.
The Perspectives on Process Safety Around the World symposium highlights process safety challenges and solutions from different regions. Can you share some of the key global trends or innovations in process safety that will be discussed at this year’s event?
This year’s Perspectives on Process Safety Around the World symposium was designed to balance practical insights with forward-thinking innovations. Key topics will include critical control management, as we look at adapting the International Council for Mining and Metals (ICMM) guidance to process safety. In the area of technology, we'll be exploring how artificial intelligence (AI) can enhance hazard identification and risk assessment. Another key topic is process safety in smelting operations, and we'll be addressing the specific challenges of process safety in high-temperature smelting operations. The symposium will also offer a fresh perspective on process safety management, rethinking traditional risk management approaches. We'll also be taking a close look at the Brazilian Institute for Mining and. Metals (IBRAM) guidelines, for specific insights into this approach to implementing process safety in mining. Additionally, in the area of managing transient operations, we'll help establish a better understanding of the risks associated with non-steady state processes.
Learn more about the 2025 Spring Meeting and 21st GCPS.
Join the conversation on Twitter and Facebook | #GCPS #AIChESpring