| WASTE ORIGIN |
WASTE
TYPE |
POLLUTION
PREVENTION AND RECYCLING METHODS |
| Material Input, Storage and Handling |
Shelf-life Expired,
Obsolete, or Contaminated Materials Reacted,
Polymerized or Off-spec Chemicals
Dust Emissions
Empty Containers
Tanker Heels |
- Test materials first to determine whether they can be used
in current manufacturing processes.
- Return obsolete materials to suppliers.
- Segregate waste streams.
- Store packages to protect from weather.
- Provide secondary containment (and possibility for recovery)
for hazardous materials.
- Reformulate products from powder to pellet.
- Switch to reusable containers, tote-bins or bulk shipments.
- Recover product from tank cars and tank pumps and piping
systems to transfer liquids.
- Use dry disconnects.
|
| Reactors |
Off-spec Materials
By-products |
- Provide separate reactor for recycled streams.
- Improve heating and cooling techniques for reactor.
- Improve control to maintain optimal conditions in reactor
(e.g., stabilize conditions in operation frequently, use advanced computer controls).
- Ensure that rubber gaskets are not cracked or worn.
|
| Pumps |
|
- Recover seal flushes and purchase and recycle to process
where possible.
- Turn off flush when not in use.
|
| Heat Exchangers |
Off-spec Product
(e.g., temperature sensitive) |
- Reduce tube-wall temperature:
- Use lower pressure steam;
- Monitor exchanger fouling.
- Use non-corroding tube.
|
| Distillation Column |
Impure Product
Polymerized Waste
Vented or Flared Products |
- Increase reflux ratio if column capacity is adequate.
- Retray or repack column.
- Insulate.
- Remove overhead products from tray near top of column.
- Increase size of vapor line.
- Modify reboiler design (falling film or pumped recirculation
reboilers, high-flux tubes).
- Ensure that tubes are not blocked.
- Lower column pressure.
|
| Piping |
Leaks and Volatile
Emission By-Products
Emissions
Degraded Product |
- Establish a leak detection and repair system for all valves,
pumps and seals.
- Avoid sending hot materials to storage.
- Avoid overheated lines, vessel tracing and jacketing.
- Segregate wastes and recover.
|
| Processing, etc. |
Off-spec Product
Contaminated Product
Spills
Dust Emissions
Evaporative Loss
Samples from Quality Control Testing |
- Produce only the amount requested or needed.
- Substitute less toxic or non-toxic raw materials.
- Improve on-line control (e.g., with computer control
system).
- Optimize daily operation.
- Automate start-ups, shutdowns and product changeover.
- Find a market for waste product.
- Install reusable insulation.
- Segregate and reuse dust emissions in the production
process.
- Review sampling frequency and procedure to reduce number and
quantity.
- Recycle samples.
|
| Laboratory Wastes |
Sample Waste Mercury |
- Reduce sample size.
- Review sampling procedures.
- Return unused sample to process (or client).
|
| Cooling Towers |
High Chemical Use
High Water Usage |
- Continuously monitor water quality and adjust chemical
concentration.
- Use less toxic biocides instead of chlorine.
- Use blowdown water for non-critical cleaning applications or
as fire pond water.
|
| Equipment Cleaning and Changeover |
Waste Product
Spent Cleaners
Rinse Water
Spent Filters |
- Maximize equipment dedication.
- Improve scheduling of production of chemicals that use the
same production line.
- Recover more product (e.g., through scraping down tanks,
pigging or blowing lines).
- Reuse inert ingredients when flushing solids handling
equipment.
- Consider less hazardous cleaners (e.g., ultrasonic cleaning
with more biodegradable cleaner).
- Standardize cleaning products used.
- Use multiple stage rinsing.
- Reuse rinse water.
- Clean process equipment with process fluids if possible.
|
SOURCE: CHEMALLIANCE
http://www.chemalliance.org/Columns/Improving/P2_Options_for_Chem_Manufacturers.htm |
