Researchers looking for cost-effective ideas for improvement should first become familiar with the sites described in the Basic Chemicals fact sheet in this series. Case studies of synthetic resins and fibers production are often mixed in with other subsectors of the chemical industry. Also, many of the cleaner production options from general chemical manufacturing are applicable in this subsector. This subsector does not have prominent trade associations or environmental programs of its own; some of the general chemical industry associations and programs have subsector information.
The table below lists solutions to reduce waste and pollution in synthetic resins and fibers production. Company environmental programs should demonstrate that these options have been considered thoroughly. Direct links to online guides to synthetic resins and fibers production follow the table.
Cleaner Production Solutions to Increase Efficiency and Reduce Waste in Synthetic Resin and Fiber Production
| Spill and Leak Prevention | Large amounts of process chemicals can evaporate through tiny leaks in equipment and storage devices. Selection and maintenance of storage, transfer, and processing equipment can effectively minimize losses. Employee training is also critical to prevention efforts. |
| Process Optimization/Quality Control | Significant waste reductions can be achieved through better quality control. The use of statistical process control, automation, and employee training can lead to a more efficient operation. Because the cost of generating off-spec material includes the cost of the raw materials, all the labor and overhead associated with processing that material, and the disposal costs, it is quite apparent that this is an area that can provide significant economic benefits. |
| Improve catalyst | Using a more active catalyst and purchasing catalysts in the active form can reduce catalyst consumption and decrease emissions generated during catalyst activation. Catalyst activity can also be optimized by limiting catalyst residence time in the charge lines |
| In-process Recycling | Vapors of styrene and solvents can be recovered for reuse. Equipment cleaning waste may be reused in some manner. If styrene is used as the solvent, the solvent wash can be collected, stored, and reused in the next batch of the same product, displacing virgin styrene. If that is not possible, the spent solvent wash can be recycled with a solvent distillation unit. |
| Alternative Cleaning Methods | Heated caustic solutions can work in limited situations. Residues in equipment can be removed prior to rinsing by the use of wiper blades or squeegees. These residues can be collected and reused. The volume of cleaning waste can also be reduced by using low volume high efficiency cleaning systems, such as high pressure spray nozzles and steam jennies. |
| Inventory Control | Many of the ingredients and products have a limited shelf life, and can become unusable. Efficient management of purchasing and production activities can prevent the expiration of materials and reduce waste. |
Source: Chemical and Allied Products Sector Analysis
http://www.dnr.state.ga.us/dnr/p2ad/pblcations/chemical/toc_ch.htm
LINKS
Technical Guides to Pollution Prevention
Profile of the Plastic Resins and Man-made Fibers Industry is the most
comprehensive guide on this sector.
(http://es.epa.gov/oeca/sector/index.html#plast).
Polyester Resin Manufacturing and Polyester Resin Operations are guides to air quality
compliance from the San Francisco Air Quality Management District. They have extensive
technical information on compliance standards and manufacturing processes.
http://www.baaqmd.gov/permit/handbook/resin.htm
The EPA publishes Plastics Materials, Synthetic Resins, and Nonvulcanizable Elastomers
Manufacturing Statutory and Regulatory Summaries that describe applicable regulations and
standards for the industry.
http://es.epa.gov/oeca/ccsmd/plast.pdf
An Analysis of Pollution Prevention Opportunities and Impediments in the Chemical and
Allied Products Sector in Georgia is one of the best technical overviews of cleaner
production opportunities in the sector.
http://www.dnr.state.ga.us/dnr/p2ad/pblcations/chemical/toc_ch.htm
Envirosense has many case studies of resin and synthetic fiber production on line.
http://es.epa.gov/cgi-bin/search.pl?studies=on
Case studies:
Recovery of Isopropyl Alcohol in the Production of Nylon Yarn
http://www.emcentre.com/unepweb/tec_case/chemical_24/recovery/r8.htm
Cleaner Production in a Polyester Plant
http://www.emcentre.com/unepweb/tec_case/chemical_24/process/p27.htm
Reducing Waste in Polyester Production
http://www.emcentre.com/unepweb/tec_case/chemical_24/recovery/r9.htm
Waste Minimization at a Plant Producing Nylon 6
http://www.emcentre.com/unepweb/tec_case/chemical_24/process/p12.htm
Manufacturing Plant Reworks Resin Waste and Virtually Eliminates Disposal
http://es.epa.gov/studies/hml10317.html
Major Sites Devoted to the Chemical Industry and the Environment
ChemAlliance is a primary site focused on regulatory information for the chemical
industry with articles, news, and regulatory assistance tools.http://www.chemalliance.org/US EPA maintains the
Chemical Manufacturing Industry assistance website with various compliance tools.
http://es.epa.gov/oeca/ccsmd/chempull.html
The UK Chemical Industry Environmental Best Practices project has many case studies
online.
http://www.etbpp.gov.uk/chemicals/index.htm
The Chemical Industry Team of the US Office of Industrial Technologies focuses on new
technologies for competitiveness as well as sustainability.
http://www.oit.doe.gov/chemicals/
ChemSafety.Gov is a website focused on promoting chemical safety in industry and homes.
http://www.chemsafety.gov/
Institute for Chemical Process and Environmental Technology is focused on cleaner
production methods.
http://www.icpet.nrc.ca/index_e.html
EPA Green Chemistry Network has many resources including an expert guide to process
design.
http://www.epa.gov/opptintr/greenchemistry/index.htm
Center for Waste Reduction Technologies is specifically focused on cleaner production.
http://www.aiche.org/cwrt/
Agency for Toxic Substances and Disease Registry is a primary source for information on
the health effects of industrial chemicals.
http://www.atsdr.cdc.gov/
EPA Chemical Fact Sheets give basic information about the risks and management of many
chemicals.
http://www.epa.gov/opptintr/chemfact/
Chemical Safety Crossroads has information on chemicals, reports, tools and software.
http://www.crossroads.nsc.org/
SafetyNet is a major European program on chemical process safety.
http://platon.imk.com/safety/
The UN-ECE Chemical Industry project has a good but old website but is getting
outdated. The new website should be good when it is finished.
http://www.unece.org/indust/chem.htm.
Old site: http://www.unece.org/trade/entdev/chemical-main.htm
Chemical and Polymer Industry Environmental Links are from the Ohio EPA.
http://www.epa.state.oh.us/opp/tarp/chem.html
This links page for the chemical industry gives quick access to most of the leading
chemical companies, many of whom are putting their environmental reports on line to share
information.
http://www.processassociates.com/sites/links.htm
Chemical Industry Trade Associations On-Line
The American Chemical Society has extensive information on Green Chemistry as well as
traditional chemistry topics.
http://www.acs.org/
The European Chemical Industry Home Page is a portal for that region.
http://www.cefic.be/
American Institute of Chemical Engineers offers many environment publications and
activities.
http://www.aiche.org/
The Chemical Industry Home Page has links to most of the major chemical industry
assocations around the world.
http://www.neis.com/associations.html
Synthetic Organic Chemicals Manufacturer's Association is the national trade
association representing the legislative, regulatory, and commercial interests of some 250
companies that manufacture, distribute, or market organic chemicals.
http://www.socma.org/
Chemical Specialties Manufacturers Association represents over 400 companies engaged in
the manufacture, formulation, distribution, and sale of chemical specialty products for
household, institutional, and industrial use.
http://www.csma.org/
The International Council of Chemical Associations (ICCA) is a council of leading trade
associations representing chemical manufacturers worldwide.
http://www.icca-chem.org/
The Commercial Development and Marketing Association is dedicated to fostering,
promoting and sharing business processes in the chemical and allied industries.
http://www.cdmaonline.org/
The Chemical Industry Search Engine has links to over 50,000 sites.
http://www.chemindustry.com/index.asp
ChemIndustry.Com is a directory of chemical industry resources.
http://www.chemindustry.com/index.asp