Cheremisinoff Waste Minimization and Cost Reduction for the Process Industries

1. Auflage 1995
ISBN: 978-0-8155-1952-2
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 348 Seiten

The purpose of this book is to provide a base of information and analysis to assist in implementation of the policy of reducing and/or minimizing hazardous waste generation in manufacturing and more specifically in the process industries. What is the significance of reducing the generation of all process wastes? This book examines the technical nature of waste reduction and the extent to which waste reduction can likely be implemented. Also explored is the extent to which technology itself, as well as information and resources, is a barrier to waste reduction. In what ways are waste reduction decisions dependent on specific circumstances? Can the amount of feasible waste reduction be estimated? Auditing of manufacturing and unit operations and processes are particularly significant and useful in the chemical process industries (food, pharmaceuticals, chemicals, fertilizer, petrochemicals, etc.) since it is estimated that these industries account for more than half of the hazardous wastes generated. This book presents a compilation of complete information on potential sources of waste loss or generation through technical inspection. Also presented are calculation methods for determining air-waste-solid wastes material balances, informational requirements and waste reduction analysis.The reader should find the book useful in the areas of auditing and waste minimization. It is replete with useful information as well as specific case histories, which should make it a practical tool for the user.

Autoren/Hrsg.

Cheremisinoff, Paul N.

Inhaltsverzeichnis

1;Front Cover;1
2;Waste Minimization and Cost Reduction for the Process Industries;4
3;Copyright Page;5
4;CONTENTS;10
5;Chapter 1. Waste Reduction;20
5.1;Background;27
5.2;Objectives;29
5.3;Prevention and Control;29
5.4;International Dimensions;33
5.5;Waste Reduction Methods;33
5.6;Broad Approaches to Waste Reduction;34
5.7;Waste Reduction Examples;38
5.8;Waste Reduction Decisions;41
5.9;Technology and Information;47
5.10;How Much Waste Reduction;50
5.11;Waste Reduction Data;53
5.12;Information Needs;54
5.13;Waste Reduction Information;59
5.14;Measure Waste Reduction;61
5.15;Hazardous Waste Reduction;63
5.16;International Perspective;68
6;Chapter 2. Auditing;71
6.1;Environmental Factors and Audit Summary Checklist;72
6.2;Overview;74
7;Chapter 3. Waste Minimization Data/Information Requirements—A General Approach For Manufacturing;92
7.1;Getting Started—Step 1;92
7.2;List Process Steps and Identify Wasteful Streams;95
7.3;Analyzing Process Steps—Preparing Process Flow Charts;95
7.4;Material and Energy Balances;98
7.5;Technical Feasibility;104
7.6;Environmental Aspects;107
7.7;Implementation Solutions;107
7.8;Monitor and Evaluate Results;108
7.9;Audit Studies—Summary Section;109
7.10;Identification Required of Water Pollution Sources for Waste Reduction/Minimization Potentials;115
8;Chapter 4. Estimating Releases To The Environment;123
8.1;Data to be Determined;123
8.2;Sources of Wastes/Releases;123
8.3;Overview of Analysis;125
8.4;Definitions of Major Approaches;127
8.5;Observations on the Use of Data;128
8.6;Approach to Use;129
8.7;Estimating Releases to Air;132
8.8;Sources of Release to Air and Release Estimation Methods;132
8.9;Estimating Releases in Wastewater;145
8.10;Sources of Wastewater and Methods for its Disposal;145
8.11;Sources and Disposal Methods for Solid. Slurry and Nonaqueous Liquid Wastes;157
8.12;Methods for Calculating Releases in Solid, Slurry and Nonaqueous Liquid Wastes ;159
9;Chapter 5. Waste Questionnaires—Water Control Checklist;165
9.1;Model Questionnaires;166
9.2;Environmentally Safe Layout for Manufacturing Units;175
9.3;Guidelines to Minimize Material Losses and Wastes;177
10;Chapter 6. Analysis Of Process Chemistry Example Processes;181
10.1;Draft Report;184
10.2;Post Audit Activities;184
10.3;Evaluation;184
10.4;Acetic Acid by Methanol Carbonylation;186
10.5;Acetaldehyde by Liquid-Phase Ethylene Oxidation;204
10.6;Process Descriptions for Oxidizing Ethylene to Acetaldehyde;207
10.7;Process Chemistry;213
11;Chapter 7. Industry Profile—Fertilizers;241
11.1;Introduction;241
11.2;Manufacturing Processes;243
11.3;Generation of Impurities and Pollutants;274
11.4;Pollutant Pararnete—Effects;281
11.5;Abatement of Pollution;288
12;Chapter 8. Treatment Of Effluent Fertilizer Industry Example;304
12.1;Nitrogenous Pollutants;304
12.2;Ammoniacal Nitrogen;305
12.3;Organic Nitrogen;322
12.4;Oxidized Nitrogen;324
12.5;Other Constituents;324
12.6;Recovery, Reuse and Recycle in the Process;339
12.7;House Keeping;342
12.8;Separation Technologies for Removal of Organic and Pesticidal Chemicals from Wastewater;343
13;Index;344

Leseproben

Chapter 2

Auditing

Auditing is an umbrella term used to describe the procedure which systematically and objectively reviews a given situation. This meaning can be very broad and there are many different types of audits. Virtually every situation and every type of operation can be audited. The nature of an audit is such that it can be tailored to meet a specific need. Nonetheless, there are some similarities and recurrent themes to group types of audits. While the reasons for initiating an audit program may vary, the benefits realized almost always include improved regulatory compliance, an increased awareness of environmental conditions, programs, improved relations with both regulatory agency and the public, a reduction in risks and potential liabilities, increased management efficiency, reduction of wastes.

Due to the nature of the information that an audit can provide, and the importance placed on the results, common sense dictates that careful consideration and planning precede the actual performance of the audit, rather than being performed in a nonchalant manner. Preplanning makes sense since substantial expenditures of capital, time, and potential liabilities may be associated with these audits. Deficiencies of audits are most commonly due to an improper or unclear scope, or an inadequate auditing team. In order to keep the costs as minimal as possible, it is essential for the scope of the audit to be defined as early as possible. Audits may result in questionable results that are irreversible or, at best, difficult to refute. Therefore, the audit process chosen must be considered carefully in order to insure the required expertise to deliver the scope of work.

This book provides a guide of environmental auditing, and describes those elements to be evaluated in auditing and to a review of observations to be included during the actual audit as well and is focused on waste minimization and reduction for its goals. The contents are focused on waste reduction for the process industries. The intention is providing the reader with some insight into the reasons behind auditing, and the individual components that are required for a successful audit. The reader will have a fuller understanding of the capabilities, as well as the limitations of an audit, and the audit may yield the maximum value possible. Also provided are specific examples for waste reduction and minimization.

The following checklist provides some of the considerations critical for site location and factors. It must be remembered that no two locations, businesses or industries are identical. Each auditor will view this checklist differently and may want to modify it to suit specific requirements.

ENVIRONMENTAL FACTORS AND AUDIT SUMMARY CHECKLIST

Historic Data

 Location, name and types of industry

 Past and present ownership

 Past and present uses

 Regulatory history

 Regulatory permits

 Products

 Raw materials

Considerations Based on Anticipated Change in the Environment

 Discharges – gaseous – liquid – solid wastes; what are the ecological considerations?

 Existing area ecological relationships (use available background data and augment as necessary)

 Control measures to minimize environmental effects

 Terrestrial and aquatic areas

 Physical tolerance levels – ambient air quality standards – water quality standards– noise level standards – glare and/or lighting standards

 Nutrients

 Detrimental and beneficial development

 Buffer zones and green belts

Water Supply

 Water needs – process – cooling – potable – fire protection

 Water availability – public water supply – private water supply – ground water surface water

 Ground water geological potential

 Water characteristics – chemical – bacteriological – corrosiveness

 Water distribution – amount available – pressure – variations – proximity to site – size of lines

 Cost of water supply – extension of existing service – development of new supply –extension of existing service – development of new supply – cost per 1,000 gallons

 Water treatment requirements – process – cooling – boiler feed– water – potable other

 Special considerations – restriction on use – future supplies – compatibility for use in process.

Wastewater Disposal

 Sewerage systems – stormwater – cooling water – process waste water

 Anticipated mode of occurrence, flow and characteristics of plant wastewater discharge

 Proposed pollution loadings

 Toxic materials present

 Variations in wastewater treatability

 Inplant control measures

 Onsite wastewater treatment and disposal possibilities

 Existing stream quality

 Water uses to be protected

 Stream quality standards

 Wastewater effluents standards

 State regulatory agencies concerned

 Stream flow characteristics, design critical flow

 Development of treatment design parameters

 Availability of a public sewerage system

 Pretreatment requirements if discharged to public sewers

 Sewer service charges and surcharges for industrial wastewaters

 Onsite underground disposal system – percolation rates

 Scavenger hauling of liquid wastes

 Emergency operation – electric power dependability

 Performance reliability requirements

Air Pollution Control Considerations

 Regional airshed standards

 Air pollution standards

 Local air pollution enforcement regulations and ordinances

 Meteorological conditions – wind direction and velocity variability, inversion frequency intensity and height, and other microclimatology factors

 Proximity to population/employment centers

 Local topography

 Effect other area industrial emissions may have on the quality of plan environment or on allowable emission rates

Solid Waste Disposal

 State and local regulations

 Disposal facilities available – incineration – sanitary landfill – other

 Local contract pickup and disposal – municipal control – competition between haulers

 Costs of solid waste disposal

 Dependability – lifetime of disposal facilities – probability of flooding

 Onsite disposal – incineration – landfill

 Responsibility – public collector – private collector – other disposal

 Special handling and disposal practices required for industrial wastes

In–Plant Operations

 General Housekeeping

 Ventilation adequacy

 Worker training adequacy

 Labeling, placarding, drum/package identification

 Raw material and product storage

 Safety

 Noise levels

OVERVIEW

Environmental audits are an unbiased evaluation of a site, operation or facility to determine whether real or potential threats of environmental contamination exist and a basis for waste minimization or reduction possibilities. Involved is prioritizing those areas at a site or facility where contaminants are generated so that a plan for prevention and remediation may be developed and implemented.

Several types of environmental or process audits are possible. Audits are differentiated by their respective goals and may use different approaches to accomplish goals. Audits discussed and emphasized...