industry and environment - DTIE

More documents

Recommendations

Info

Chemicals management related to projects that were part of the case study but also routine experimentation where environmental considerations needed to be taken into account. This advisor-researcher interaction was very useful. However, the company’s organizational structures (taking advantage of synergies, multifunctionalism) led to the decision that researchers themselves should be the driving force behind DfE implementation while the divisional group advised on specific aspects. During this stage of the research process, a group that had not been expected to be an active participant in DfE implementation became important: those actually operating the pilot plant. Once the researcher defines the formulations, plant operations become the responsibility of other personnel. The pilot plant’s activities were focused on identifying opportunities to optimize materials and energy through cleaner production. Cleaner production is an extremely useful tool for identifying eco-efficiency opportunities. 4 The equipment designed for experimentation at the pilot stage is usually adequate for the researchers’ routine tests, but it was not entirely adequate for the measurements required by DfE. Thus, the advisor made several theoretical computations that resulted in difficult and extended work. While the advisor played an important role in DfE implementation, plant personnel should perform these tasks in future work. Results obtained at subsequent stages are summarized in Figure 4. Each stage lasted two full years. Regarding the project that was in its commercial phase, no progress was possible. Some concern exists about involving the client in something new and presenting it to him upon completion of research. Clients should be involved in DfE from the very beginning; when initial research is presented, the evaluation that will be carried out should be stated and the client should recognize the added value to be gained from DfE. Stages of DFE Feasibility study Technological monitoring Pilot tests Industrial scale tests Marketing Commercialization would be required in the process. However, at 35% concentration the compound showed hazardous characteristics; at a concentration of 30% it presented no hazard. The lower concentration necessitated the use of a greater amount of the compound. As it was non-hazardous, the risk to communities during transport was eliminated, along with the higher costs of hazardous materials transport. The lower concentration was therefore recommended. Figure 4 Outcome (2001-2002) HOT MELTS ✔ Replacement of solvents with materials less hazardous to the environment ✔ Social perception and environmental impact of final product were the main elements influencing restart of research work with another product STYRENE BUTADIENE RUBBER Through cleaner production, the following points were identified and quantified: ◆ 84% of raw materials used in pilot plant were disposed of as wastes ◆ Evaporation losses equivalent to $1000/day-batch ◆ Energy saving opportunities translated into costs: around $1000/day-batch STYRENE BUTADIENE RUBBER ◆ Detection of logistical opportunities for import of a raw material Benefits gained when the lower concentration is chosen Environmental and safety benefits ◆ hazardous waste reduction, as 84% of the oxidant consumed eliminated as waste; ◆ reduced consumption of chemical compounds required to treat wastewater produced by excessive acid consumption; ◆ reduction of risks to workers during product handling; Process description Figure 2 shows the process of modified rubber formulation. In the reaction stage the rubber is manufactured from monomers and other organic compounds. The research project consisted of incorporating an intermediate stage called “modification” in which the rubber is modified with oxidizing processes to improve its properties. The final stage is coagulation, washing and drying, in which aliphatic solvent (a type of hydrocarbon) is recovered. DfE contributions were as follows: Modification stage ◆ Two oxidative compounds with corrosive characteristics and highly oxidizing properties were evaluated. One contained halogenated materials as impurities, which made it less environmentally friendly. The most environmentally friendly compound was chosen. ◆ This compound was submitted for analysis, as a choice needed to be made between two possible concentrations. The highest concentration was considered feasible, as a smaller amount of it Benefits from choosing the most environmentally friendly compound Environmental and safety benefits ◆ air pollution not increased; emissions of halogenated organic vapour eliminated; ◆ use of chemical products reduced (in this substance’s liquid form, as opposed to the solid form of the other compound, no solvent is required for dilution); ◆ elimination of probable chronic exposure of personnel to halogenated compounds; Social benefits ◆ elimination of risks to the community related to emissions of halogenated organic vapours during transport; Product profitability ◆ reduced generation of environmental emissions (air, water); avoidance of use of a material requiring investment in the control and reduction of emissions of halogenated compounds; ◆ reduced transport costs, as handling of hazardous materials not required; Benefits for the pilot plant process Energy ◆ pilot tests carried out at same location where rubber is manufactured (Altamira), to take advantage of heat generated during the process and to avoid additional consumption of energy at the plant during the modification stage; Product profitability ◆ energy consumption savings if the pilot test is carried out at the same location where rubber manufactured; Benefits at the coagulation stage Environmental and safety benefits ◆ no increased generation of photochemical smog; emissions of organic vapours of the aliphatic solvent eliminated at pilot plant; Product profitability ◆ considerable savings opportunities due to identification of losses (around 90% of aliphatic solvent when separated by evaporation during coagulation stage, due to faulty operation during 50 ◆ UNEP Industry and Environment April – September 2004
Chemicals management its recovery); it is necessary to modify the pilot plant to avoid these losses. Capitalizing on experience for use in education Conclusions at the end of the third stage can be summarized as follows: ◆ Incorporating DfE concepts requires a link to the researchers’ work if this technology is to be incorporated in a practical way. Under the DfE scheme they not only learn, but a total transformation of their beliefs occurs (with an environmental vision now basic to their work); ◆ Of course, it is also necessary that researchers learn about the subject through reading and, above all, attending forums where they can share experience with their peers; ◆ A change in pilot plant structures follows the incorporation of DfE in research; use of a greater number of instruments to ease the measuring work is considered; ◆ DFE is a synergy tool; not only should plant personnel be looking for savings opportunities, but for researchers it becomes a hypothesis to be corroborated; ◆ Clients are of strategic importance. They will drive environmental work when they realize the added value it provides in terms of market value, image and environmental performance. When clients are unaware of these benefits, it is up to the company to make the clients sensitive to them. That is the only way for the value added resulting from DfE implementation to be recognized. Clients, in turn, can commercialize the new product using the same environmentally related information. Notes 1. See Industry and Environment review, Vol. 25, No. 3-4 (cleaner production issue, July-December 2002), Glossary, p. 3, and passim; and Volume 26, No. 2-3 (sustainable building and construction issue, April-September 2003), passim. 2. There are many sources of information concerning the substances on these lists. See, for example, the site of the American Solvents Council (www.americansolventscouncil.org/faqs.asp). 3. www.epa.gov/dfe/pubs/tools/ dfefactsheet/dfefacts8_02.pdf. 4. See the article by Mily Cortés Posas and Nonita T. Yap on page 68. References DESC SA de CV Annual Report, 2003. Diseño para el Ambiente en la función de investigación y desarrollo de GIRSA (manual). (M. Ferat, T.-H. Martínez, M.A. Valenzuela. GIRSA Corporativo SA de CV., 2001. Exploring sustainable development. WBCD Global Scenarios 2000-2050. Summary Brochure. World Business Council for Sustainable Development (www.betterworld.com/BWZ/9610/explore.htm). Technology Vision 2020 (American Chemical Society, American Institute of Chemical Engineers, Chemical Manufacturers Association, Council for Chemical Research, Synthetic Organic Chemical Manufacturers Association), 1996 (www.ccrhq. org/vision/welcome.html). ◆ UNEP Industry and Environment April – September 2004 ◆ 51
Page 1 and 2: UNEP ISSN 0378-9993 Industry and En
Page 3 and 4: E d i t o r i a l Balancing the ben
Page 5 and 6: Chemicals management priority basis
Page 7 and 8: Chemicals management Global strateg
Page 9 and 10: Chemicals management The Rotterdam
Page 11 and 12: Chemicals management Chemicals subj
Page 13 and 14: Chemicals management Figure 2 Test
Page 15 and 16: Chemicals management substances wit
Page 17 and 18: Chemicals management they may migra
Page 19 and 20: Chemicals management Integrated che
Page 21 and 22: Chemicals management ◆ supporting
Page 23 and 24: Chemicals management The Montreal P
Page 25 and 26: Chemicals management Softening the
Page 27 and 28: The future of pesticide use in worl
Page 29 and 30: Chemicals management The first Dani
Page 31 and 32: Chemicals management ferred easily
Page 33 and 34: Effects of an environmental tax on
Page 35 and 36: Chemicals management the prices of
Page 37 and 38: Chemicals management The Africa Sto
Page 39 and 40: Chemicals management The evolution
Page 41 and 42: Chemicals management potential, how
Page 43 and 44: Chemicals management Cleaner produc
Page 45 and 46: Chemicals management gases such as
Page 47 and 48: Chemicals management Implementation
Page 49: Chemicals management Aliphatic comp
Page 53 and 54: Chemicals management Figure 1 Drum-
Page 55 and 56: Chemicals management Annual energy
Page 57 and 58: Chemicals management GREENPEACE/MOR
Page 59 and 60: Chemicals management the dirtier op
Page 61 and 62: Chemicals management and cleaning o
Page 63 and 64: Chemicals management Achievements o
Page 65 and 66: Chemicals management Transparency a
Page 67 and 68: Chemicals management Communication
Page 69 and 70: Other topics promoting and establis
Page 71 and 72: Other topics Training courses The C
Page 73 and 74: Other topics 4. Identification of I
Page 75 and 76: Other topics Technical consideratio
Page 77 and 78: N e w s plagued industrialized coun
Page 79 and 80: N e w s ered paper to make their pr
Page 81 and 82: N e w s Saving the world’s seas a
Page 83 and 84: N e w s Measuring Your Company’s
Page 85 and 86: N e w s Responsible Care Canadian C
Page 87 and 88: THE UNEP DIVISION OF TECHNOLOGY, IN

industry and environment - DTIE

Create successful ePaper yourself

Delete template?

Save as template?