2008 Sector Performance Report - US Environmental Protection ...

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ChemiCal manufaCturing 1 AT A GLANCE 1996-2005 12,377 facilities 13,220 7% 833,230 employees 810,368 3% $368 billion value of shipments $555 billion 51% 26 Chemical Manufacturing 2008 SECTOR PERFORMANCE REPORT
Latest Environmental Statistics 2 Energy Use: 3.8 quadrillion Btu Emissions of Criteria Air Pollutants: 1.5 million tons Releases of Chemicals Reported to TRI: 540.8 million lbs. air emissions: 201 million lbs. Water Discharges: 42.7 million lbs. Waste Disposals: 297 million lbs. Recycling, Energy Recovery, or Treatment: 10.9 billion lbs. Hazardous Waste Generated: 23.8 million tons Hazardous Waste Managed: 26.1 million tons The data discussed in this report are drawn from multiple public and private sources. See the Data Guide and the Data Sources, Methodologies, and Considerations chapter for important information and qualifications about how data are generated, synthesized, and presented. Profile Chemical Manufacturing facilities transform raw materials (e.g., oil, natural gas, water, minerals, metals) into tens of thousands of different products, including bulk chemicals, plastics, pharmaceuticals, and consumer goods, as well as produce inputs to agriculture, manufacturing, and construction industries. The sector is categorized into “commodity” and “specialty-batch” production. 3 • Commodity manufacturers create products in large quantities under continuous processing conditions. The small number of shutdowns affects the potential to make adjustments such as equipment retrofits and upgrades. • Specialty-batch manufacturers develop products for particular “niche” markets, making complex products in small quantities. These manufacturers change their process lines several times per year, providing more opportunities for environmental improvements but also making environmental compliance more complicated. In this report, the specialty-batch subsector is characterized by a facility list based on membership with the Synthetic Organic Chemical Manufacturers Association (SOCMA). 4 Throughout this chapter, the distinction is made between “all chemical manufacturing” and “specialty-batch manufacturing,” whenever separate data are available. “All chemical manufacturing” includes both commodity and specialty-batch processors. The sector represents about 12% of all U.S. manufacturing revenue based on value of shipments (VOS). Energy Use Chemical Manufacturing is an energy-intensive sector, using a total of 3.8 quadrillion Btu in fuel for energy purposes. Along with using fuels to supply the energy needs of facility operations, the sector uses fossil fuels—primarily natural gas and oil—as raw materials in the production of many products. Organic chemicals require the most fossil fuel. Feedstock use of fossil fuels is also common in the bulk petrochemical and fertilizer industries. 5 Figure 1 Fuel Use for Energy 2002 Other 31% Total: 3.8 quadrillion Btu Net Electricity 14% Residual Fuel Oil 1% Natural Gas Coal 8% 45% Liquified Petroleum Gas and Natural Gas Liquids 1% Notes: 1. Other is net steam (the sum of purchases, generation from renewables, and net transfers), and other energy that respondents indicated was used to produce heat and power. 2. Net electricity is an estimation of purchased power and power generation onsite. Source: U.S. Department of Energy 2008 SECTOR PERFORMANCE REPORT Chemical Manufacturing 27
Page 1 and 2: 2008 Sector Performance rePort
Page 3: table of Contents i Preface 1 Execu
Page 6 and 7: Key to our work is collaboration wi
Page 8 and 9: Energy Use The eight sectors for wh
Page 10 and 11: Sector Data Side by Side The follow
Page 12 and 13: TRI Air Emissions Across Sectors 19
Page 14 and 15: TRI Waste Management Across Sectors
Page 16 and 17: This report relies upon a variety o
Page 18 and 19: TABLE 3 Economic Activity Data for
Page 20 and 21: Presentation of TRI Air Emissions D
Page 22 and 23: Presentation 500,000,000 of TRI Was
Page 24 and 25: Cement Manufacturing 1 AT A GLANCE
Page 26 and 27: equires 32% more energy per ton of
Page 28 and 29: Summing the Toxicity Scores for all
Page 30 and 31: l t , r t i t i Figure 3 Cement Kil
Page 34 and 35: Chemical facilities purchase electr
Page 36 and 37: conservatively assumes that chemica
Page 38 and 39: Balanced Water Use at BASF Supply U
Page 40 and 41: Waste Management Reported to TRI In
Page 42 and 43: Colleges & universities 1 AT A GLAN
Page 44 and 45: Criteria Air Pollutants Most CAP em
Page 46 and 47: Construction 1 AT A GLANCE 1996-200
Page 48 and 49: Figure 1 Fuel Use for Energy 2002 E
Page 50 and 51: Figure 4 Trends in Construction and
Page 52 and 53: Food & Beverage Manufacturing 1 AT
Page 54 and 55: Figure 2 Air Emissions Reported to
Page 56 and 57: associations, or government agencie
Page 58 and 59: disposed or released to air or wate
Page 60 and 61: Forest Products 1 AT A GLANCE 1996-
Page 62 and 63: 2002 the manufacture of wood produc
Page 64 and 65: emission controls to the pulping, p
Page 66 and 67: Water discharges became a major foc
Page 68 and 69: Iron & Steel 1 AT A GLANCE 1996-200
Page 70 and 71: ton of steel shipped improved over
Page 72 and 73: existing, high-toxicity weighting f
Page 74 and 75: water that has been reused. Typical
Page 76 and 77: Metal Casting 1 AT A GLANCE 1996-20
Page 78 and 79: using a cupola furnace can dehumidi
Page 80 and 81: Table 1 presents the top TRI-report
Page 82 and 83:
Waste Management Reported to TRI hi
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Oil & Gas AT A GLANCE 1996-2005 1,2
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equipment helps recover the gas. In
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The most widely used EOR technique
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Petroleum refining Latest Environme
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Figure 2 Al TRI HA s Air Emissions
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energy technologies, and improving
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Paint & Coatings 1 AT A GLANCE 1996
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Figure 1 Air Emissions Reported to
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Owned Treatment Works, but may also
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Ports 1 AT A GLANCE 2005: 360 publi
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Increasing Use of Solar Power The P
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developing retrofit and replacement
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“invasive” if they are capable
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shipbuilding & ship repair 1 AT A G
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of marine coatings. CAPs and GHGs a
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Table 1 Top TRI Air Emissions 2005
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Shipyards’ stormwater runoff is t
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data Sources, Methodologies, and CO
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Facilities described above must rep
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Data Processing RSEI calculates tox
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• Section 6.2: Transfers to other
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Cement Manufacturing 1. Facilities:
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12. Charles Heizenroth, EPA, person
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Forest Products 1. Facilities: Cens
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40. Includes direct discharges to w
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Public Data Release (PDR) (includes
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Advancing Port Sustainability, Janu
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