United States
Environmental Protection
Agency
Office of Water
4301
EPA-S2Q-R-94-005
August 1994
EPA International (Non-U.S.)
Industrial Pollution Prevention:
! ; " -
A Case Study Compendium
Recycled/Recyclabl
Printed with Soy/Canda Ink on
contains at least 50% recycled liber
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This project has been funded, at least in part, with Federal funds from the U.S.
Environmental Protection Agency (EPA) Office of Water under Contract No. 68-C8-
0066, WA Nos. C-2-63 (O) and C-3-63 (O) and Contract No. 68-D3-C030, WA No. O-
14. The mention of trade names, commercial products, or organizations does not imply
endorsement by the U.S. Government.
This document was developed and reproduced using recycled paper.
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TABLE OF CONTENTS
ACRONYMS i
CHEMICAL SYMBOLS iv
UNIT ABBREVIATIONS vi
INTERNATIONAL POLLUTION PREVENTION CASE STUDY COMPENDIUM 1-1
CASE STUDIES 2-1
BATTERY 2-1
CEMENT 2-2
CHEMICAL MANUFACTURING 2-7
Adhesive and Sealants Manufacturing 2-7
Inorganic Chemical Manufacturing 2-9
Organic Chemical Manufacturing 2-17
Miscellaneous Chemical 2-24
ELECTRICAL EQUIPMENT 2-26
ELECTROPLATING 2-29
FERTILIZER 2-68
FOOD 2-74
Vegetable Processing 2-74
Animal and Poultry Processing 2-83
Dairy Products 2-88
IRON AND STEEL - 2-95
LEATHER TANNING AND FINISHING 2-107
METAL PRODUCTS MANUFACTURING 2-151
Hardening 2-151
Machining • • 2-153
Pickling 2-155
Painting 2-156
MINING • 2-163
NONFERROUS METALS 2-165
PETROLEUM REFINING 2-171
PLASTICS 2-173
PRINTING 2-174
PULP AND PAPER 2-177
Wood Pulp Mills • • • 2-177
Nonwood Pulp and Paper Mills 2-278
Synthetic Fibers Pulp Mills 2-314
Paper Mills 2-326
TEXTILE 2-340
Synthetic Textiles 2-340
Wool Manufacturing 2-349
Cotton Production 2-355
General Textile 2-375
TIMBER PRODUCTS 2-392
TRANSPORTATION 2-393
MISCELLANEOUS 2-394
CASE STUDIES OF THE REUSE AND RECYCLING OF POST-CONSUMER WASTES 3-1
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APPENDICES
APPENDIX A - THE INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE
AND THE POLLUTION PREVENTION INFORMATION CLEARINGHOUSE
APPENDIX B - CASE STUDY FORMAT GUIDELINES
APPENDK C - FOREIGN CURRENCY EXCHANGE RATES
APPENDIX D - COMMON CHEMICAL ELEMENTS AND SYMBOLS
APPENDIX E - BIBLIOGRAPHY
KEYWORDS INDEX
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ACRONYMS
AD
AOX
APU
AQ
ASAM
BL
BOD
BOD5
BSH
BSS
BTRA
$CA
CAD
CERCLA
CIS
CMP
COD
CTRL
CTMP
Dfl
DK
DP
DTMPA
DTPA
EDTA
e.g.
EtOH
EPA
FF
FPPRI
FRG
HNL
ICArn
ICPIC
i.e.
ISIC
air dry
Adsorbable Organohalogens
Acid Purification Unit
anthraquinone
alkaline sulfite anthraquinone methanol
black liquor
Biochemical Oxygen Demand
Biochemical Oxygen Demand (5-day)
Blanc Stabilise Humide
Blanc Stabilise Se
Bombay Textile Research Association
Central American dollars
Canadian dollars
Comprehensive Environmental Response, Compensation and Liability Act
Commonwealth of Independent States
chemimechanical pulp(ing)
Chemical Oxygen Demand
Cotton Textile Research Laboratory
chemithermomechanical pulp(ing)
guilder (currency of the Netherlands)
Danish Kroner (currency)
degree of polymerisation
metal-(diethylenetrinitrilo) penta acetic acid
(diethylenetrinitrilo) penta acetic acid
ethlylenediamine tetra-acetic acid
for example
ethanol or ethyl alcohol
Environmental Protection Agency
French francs
Finnish Pulp and Paper Research Institute
Ministry of Research and Technology
Hindustan Newsprint Ltd.
Institute Centroamericano de Investigation y Tecnologia Industrial or the Central
American Research Institute for Industry
International Cleaner Production Information Clearinghouse
that is
International Standard Industrial Classification
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ffpp
LRP
MCC
N/A
NCC
NS
NS/AQ
NTP
OD
OECD
O&M
PAA
PGW
PGW-S
PH
PIES
PPIC
PPm
PUR
PVA
PVC
QTY
RCRA
R&D
RDH
RF
scaup
SEK
SEP
SIC
SIDA
SRP
SS
SYTYKE
T
TL
TMP
International Pollution Prevention Project
Lignon Removal Process
modified continuous cooking
Not Available
no chlorine compounds
thionitrosyl
neutral sulfite-anthraquinone
normal temperature and pressure
oven-dry
Organization for Economic Cooperation and Development
Operation and Maintenance
Polyacrylates
pressurized groundwood
super pressurized groundwood
Poly-hydrolysate
Pollution Prevention Information Exchange System
Pollution Prevention Information Clearinghouse
parts per million
Polyurethane
Polyvinyl alcohol
Polyvinyl chloride
quantity
Resource Conservation and Recovery Act
Research and Development
Rapid Displacement Heating
Radio Frequency
Sulfonated chemi-mechanical pulp
Swedish crowns
Steam Explosion Pulping
Standard Industrial Classification
Swedish Industrial Development Authority
sulfite reducing peroxyde
Suspended Solids
The Environmental Research and Development Programme for Finnish Forest
Industry
ton
Thin Layer
thermomechanical pulp(ing)
11
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TRS
TS
TSS
UF
UK
UNEP
US
USD or US$
UV
V.I.E.
YTD
total reduced sulfur
total solids
Total Suspended Solids
Ultrafiltration
United Kingdom
United Nations Environmental Programme
United States
United States dollars
Ultraviolet
volumetric isothermal expansivity
Yellow Telephone Directory (in Japan)
111
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CHEMICAL SYMBOLS ABBREVIATION LIST
Chemical Symbol
CaCO3
CaHPO
CaO
CaOH
CCljF
CH4
C12
C102
CN
CO-gas
C02
Cr(OH)3
DTMPA
DTPA
EDTA
EtOH
HC1
H2
HN02
HNQj
Hp
HjSO,
K20
MgO
MnS04
NaBH4
NaCl
NaC103
nhemical Name
aluminum sulfate
calcium carbonate
calcium hypophosphate
calcium oxide
calcium hydroxide
trichlorofluormethane or CFC-11
methane
elemental or diatomic chlorine
chlorine dioxide
cyanide
carbon monoxide
carbon dioxide
chromium hydroxide
chromium oxide
metal-(diethylenetrinitrilo) penta acetic acid
(diethylenetrinitrilo) penta acetic acid
ethlylenediamine tetra-acetic acid
ethyl alcohol
hydrochloric acid
elemental or diatomic hydrogen
nitrous acid
nitric acid
water
hydrogen peroxide (molecular formula)
hydrogen sulfide
hydrogen hexafluorophosphate or hexafluorophosphoric acid
sulfuric acid
(ortho) phosphoric acid
potassium (mon)oxide
magnesium oxide
manganese sulfate
sodium borohydride
sodium chloride
sodium chlorate
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NaHCO3
NaOH
NH3
NH4NO3
NO
N02
NOX
NP
NPK
PH3
P205
s-
SiF4
SiO2
SO,
ZnO
sodium carbonate
sodium bicarbonate
sodium hydroxide
sodium sulfite
sodium sulfate
ammonia
ammonium nitrate
nitrogen (mon)oxide or nitric oxide
nitrogen dioxide
nitrogen oxides (various)
nitrogen-phosphorus
nitrogen-phosphorus-potassium
phosphine
phosphorus pentoxide
sulfide ion
silicon tetrafluoride
silicon dioxide
sulfur oxides (various)
zinc oxide
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UNIT ABBREVIATIONS
ADMT/d (or ADMTPD)
ADt
ADt/a
ADt/d
A or amps
ac
amp/dm?
Btu
eC (or deg C)
cm
cP
dB
Dfl
Dfl/kg
g
gA
g/m3
GJ
GJ/idmt
GJ/ton(orGJ/t
or GJ/tonne)
h
hp
hr
kg
kg/AD
kg/day (or kg/d)
kg/hr
kg/m2
kg/m3
kg/ton (or kg/tonne)
kt/a
kWh/ADt
kWh/admt
kWh/m3
air dry metric ton per day
air dry ton
air dry ton per annum
air dry ton per day
amperes
acres
amperes per square decimeter
British thermal unit
degrees Celsius
centimeters
centipoise
decibels
guilders
guilders per kilogram
grams
grams per liter
grams per cubic meter
gigajoule
gigajoule per air dry metric ton
gigajoule per ton
hour
horsepower
hour
kilograms
kilogram per air dry (pulp)
kilograms per day
kilograms per hour
kilograms per square meter
kilogram per cubic meter
kilograms per ton
kiloton per annum
kilowatt-hour per air dry ton
kilowatt-hour per air dry metric ton
kilowatt-hour per cubic meter
VI
-------
kWh/ton (or KWh/t)
I
I/kg
I/kg AD
1/m2
I/ton
lakhs
Ibs
Ibs/year
m
m3
nrVd (or m3/day)
m3/ton (or m3/t
or nrVtonne)
mYyear
mg
mg/1
mg/m3
min
MJ
mm
MPa
msq ft
m2
MT
MWh/t
MWh/year
Nof/hr/m3
Pa.S
ppm
psig
rpm
s
t/a
T/day (or t/day
or tpd or t/d)
kilowatt-hours per ton
liters (also spelled litres)
liters per kilogram
liter per kilogram of air dry (pulp)
liters per square meter
liters per ton
100,000 rupees
pounds
pounds per year
meters
cubic meters
cubic meters per day
cubic meters per ton
cubic meters per year
milligrams
milligrams per liter
milligrams per cubic meter
minute
megajoule
millimeters
megapascal
million square feet
square meter
metric tons
megawatt-hour per ton
megawatt-hour per year
Newton cubic meters per hour per cubic meter
Newton cubic meter per kilowatt-hour
pascal second
parts per million
pounds per square inch, gauge
revolutions per minute
second
tons per annum
tons per day
vu
-------
tpy (or t/y)
ug/m3
um
V
VIA
v/v
tons per year
micrograms per cubic meter
micrometer
volts
volts per ampere
volume per volume
via
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INTERNATIONAL POLLUTION PREVENTION CASE STUDY COMPENDIUM
INTRODUCTION TO THE COMPENDIUM PROJECT
The U.S. Environmental Protection Agency (EPA) has joined with industry, States, and local regulatory
agencies, as well as pollution prevention experts, to implement the EPA's Industrial Pollution Prevention Project
(IPj). The IP3 is, an agency-wide, multimedia project focusing on industrial pollution prevention. The
objectives of the IP3 are twofold: (1) to incorporate pollution prevention into the industrial effluent guidelines
process, and (2) to extend information to industries and to the consuming public to better establish and spread
the pollution prevention ethic.
The IP3 includes 13 tasks, one of which is to gather together all readily available information on the
pollution prevention measures implemented by industries in other countries, to put all that information into
electronic files so that it is accessible to all interested parties, and to compile all the case studies into a hard-
copy compendium.
This compendium has been prepared by the IP3 to provide EPA, States, industries, and other interested
parties with access to non-U.S. pollution prevention case studies. The compendium includes many countries'
experiences related to a variety of pollution prevention concepts and technologies. It is hoped that this
compendium will be helpful to plant designers, managers, and regulators who are searching for creative ways to
accomplish further pollution prevention.
As indicated above, the information compiled for this hard-copy compendium is also being put into the
Pollution Prevention Information Clearinghouse (PPIC) and into the International Cleaner Production
Information Clearinghouse (ICPIC) so that it will be available electronically to all interested parties. (Although
this hard-copy compendium does not include case studies from U.S. industries, U.S. case studies may be
obtained through the PPIC.) Appendix A provides a reference guide to bom the PPIC and the ICPIC, and
Appendix B contains information on the content and format of the case studies.
APPROACH IN SELECTING THE CASE STUDIES
The case studies in this compendium have been compiled from a variety of sources, including the
following:
• United Nations Environment Programme (UNEP)
• Organization for Economic Cooperation and Development (OECD)
• Embassies and government environmental offices
• Proceedings from various international conferences on pollution prevention
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• Trade journals
• Contacts in the United States and abroad.
Over 200 case studies from more than 20 countries are included in this compendium. Before being
included, all the international case studies obtained were reviewed to ensure conformity with the concept of
pollution prevention. Pollution prevention, generally, is the multimedia approach to protecting the environment
that involves the use of processes, practices, or products that reduce or eliminate the generation of pollutants—
before recycling, treatment, or disposal. (For further discussion, see the next section—"BACKGROUND ON
POLLUTION PREVENTION.") For this compendium, only source reduction or "closed-loop" recycling was
considered to be pollution prevention.
All information obtained was reviewed to ensure that case studies included in this compendium (and added
to electronic files) would be of interest and would provide sufficient detail to be useful to intended audiences.
In some cases, materials had to be translated into English before being included.
Typically, each case study summarizes the technology used, its application, the status of the technology's
development, commercial availability, investment and operating costs, payback periods, cost savings, feedstocks
utilized, wastes produced, pollution reductions achieved, regulatory issues, and any startup or implementation
problems encountered. Whenever possible, contact names, addresses, and telephone numbers have been
provided.
It should be noted that much of the economic data included in the compendium is provided in the
currency of the country from which the case study originated. To assist readers, a table of foreign currency
rates and a table of common chemical elements and their symbols have been provided in Appendices C and D,
respectively. (Readers should keep in mind that the economic figures included in the case studies represent the
costs and savings incurred at the time each industry's activities were documented and may not reflect present
values.)
This compendium contains over 200 pollution prevention case studies within 20 broad industrial
categories, such as electroplating, chemical manufacturing, pulp and paper, petroleum refining, and textiles.
Several additional case studies have also been included in this compendium, even though they are not truly
pollution prevention as we have defined it These additional case studies do reduce or eliminate, pollutants, go
beyond traditional end-of-pipe approaches, and therefore were judged to be valuable additions to the
compendium. They have been included in the body of the compendium—but they are marked with a special
symbol to distinguish them from the truly pollution prevention case studies. Also, several case studies of
successful post-consumer recycling technologies have been included as a separate section of the compendium.
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Finally, the compendium provides a very helpful keyword index that lists the keywords included in the
case study abstracts with citations indicating the pages on which each keyword appears.
While most of the case studies demonstrate success stories, examples of failed efforts (and the reasons for
their failure) have also been included, because there is something to be learned from failures as well as
successes.
BACKGROUND ON POLLUTION PREVENTION
Historically, the U.S. EPA has relied primarily on pollution abatement programs and policies that impose
controls after the point of waste generation. This approach, commonly known as "end-of-pipe" management, is
based largely on regulations intended to treat a waste or otherwise deal with pollution prevention after it has
been generated.
In October 1990, the U.S. Congress passed the Pollution Prevention Act of 1990 (Public Law No. 101-
508, Title 6, 104 Stat. 1388). The Act encourages the prevention of pollution at the source whenever feasible.
By implementing such pollution prevention, industries may realize the following advantages:
• Lower facility operation and maintenance costs
• Savings in raw material, feedstock, and manufacturing costs
• Increased production rates and improved product quality
• More consistent compliance with Federal, State, and local wastewater discharge requirements
• Decreased treatment, storage, transportation, and waste disposal costs
• Decreased employee risk from exposure to chemicals
• Potential reduction in short- and long-term liability associated with handling and disposing of
dangerous materials
• Potential reduction in environmental impairment insurance costs
• Improved public image and employee morale from waste reduction efforts
• Significant contributions to a cleaner environment due to reduced pollutant generation.
In order for an industry to identify appropriate pollution prevention and waste reduction opportunities
(Figure 1), a facility should conduct an assessment that includes characterizing its waste stream, identifying
viable options for reducing wastes, and determining which options are technically and economically feasible.
The assessments usually include the following four phases: planning and organization, assessment, feasibility
analysis, and implementation and performance evaluation. The opportunities that should be considered are
discussed below:
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Waste
Segregation
&
Separation
1
Housekeeping
Changes
Training
and
Supervision
Production
Planning
&
Sequencing
Material/
Product
Substitution
Process/
Equipment
Modification
Figure 1. Pollution Prevention Opportunities
• Training and Supervision—Improved training and supervision of employees to help reduce or
eliminate waste generation caused by improper equipment use and maintenance. Employees directly
involved with processes and activities that generate wastes should have an understanding of why and
how the wastes are generated, how they are managed, and the costs and liabilities incurred by the
mismanagement of wastes.
• Production Planning and Sequencing—Planning and sequencing production processes such that no
step in the production process is needlessly "undone" by a later operation. Examples of such
sequencing include the sorting and rejection of parts prior to painting or electroplating or the
scheduling of batch processes to allow wastes or residues from one batch to be used as input to the
next. Improved scheduling of batch production runs reduces the frequency of equipment and tank
cleaning, which can result in less generation of waste.
• Process/Equipment Modification—Changes in a process or in the equipment used to reduce the
amount of waste generated. For example, paint overspray may be reduced by decreasing the
atomizing air pressure to paint spray equipment; the dragout of pollutants may by reduced in metal
finishing operations by reducing the withdrawal speed of parts from plating tanks. Further,
redesigning or replacing equipment may generate less waste.
• Material/Product Substitution—Substituting or replacing a hazardous or toxic substance used in a
production process with a nonhazardous or less hazardous toxic substance. Examples might include
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replacing solvent degreasers with alkali washes or substituting cyanide dip and chromium
dip/passivation lines with sulfuric acid and hydrogen peroxide bright pickle dips. Pollution
prevention steps may also mean changing a facility's intermediate or final product to generate less
waste during the production process.
Housekeeping Changes — A variety of materials handling and equipment maintenance activities that
can lead to reduced waste generation. For example, performing preventive maintenance of
equipment can improve operating efficiency and reduce the likelihood or occurrence of product
rejection or of off-specification products. Improved recordkeeping and documentation of operating
procedures promotes consistency, reducing the manufacture of unacceptable products that must be
discarded. Maintaining operating manuals may assist operators monitoring waste generation in
identifying unplanned waste releases and in responding to equipment failures. Spill and leak
prevention and control include operational procedures and precautionary modifications to equipment
and containment areas to minimiye leaks and spills.
• Inventory Control— Improved material tracking which can reduce the waste resulting from
overstocking and identify the need for disposal of material with an expired shelf life. Improved
material usage, handling, and storage can reduce loss of raw or intermediate materials due to
mishandling and improper storage.
• Waste Segregation and Separation — Management of wastes so as to segregate hazardous and non-
hazardous wastes, liquid wastes from solids, and wastestreams containing recoverable metals from
those containing chelating agents. Waste segregation and separation promotes recycling and recovery
of wastes and improves their treatability. For example, separating hazardous wastes from non-
hazardous wastes eliminates the need to treat or dispose of an entire mixture as if it were all
hazardous, thus saving treatment, disposal, and possible liability costs.
In order for an industry to optimize its use of pollution prevention measures, it should adopt a "product
life cycle management" or holistic approach to identifying and evaluating opportunities to reduce the
environmental impacts associated with a specific product, process, or activity by analyzing its entire life cycle.
Such an approach encompasses the extracting and processing of raw materials; the manufacture, transport, and
distribution of a product; use/reuse/maintenance of that product; possible recycling and composting; and final
disposal. A life cycle assessment may consist of three components:
• Inventory analysis — The identification and quantification of energy and resource use and waste
emissions
• Impact analysis— The assessment of the consequences of those wastes on the environment
• Improvement analysis— The evaluation and implementation of opportunities to effect environmental
improvements.
The results of such an assessment may lead to the redesign of an existing product or to the creation of a
new product.
While there are many potential benefits to be realized from implementation of pollution prevention
techniques, industries should be aware that they may encounter short-term obstacles that should be overcome
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during the process. For example, facilities may experience changes in production rates and/or product quality
control during equipment or procedural transition periods. Industry officials may observe changes in client
relations and product marketing as changes in product characteristics affect customer acceptance. Industries
may encounter employee resistance to onsite changes and to lack of training or experience in new equipment or
new operating processes. Onsite waste treatment systems may experience temporary adverse impacts during
transitions to different, less hazardous raw or intermediate materials. Further, if an industry has chosen to
accept another plant's waste as a feedstock for its operations (an environmentally efficient and often cost saving
practice), the industry may first need to resolve possible regulatory and liability issues as well as any potential
effects oa product quality. However, if industry officials commit to establishing a pollution prevention
program, each of these potential problems can be effectively resolved. This compendium provides examples of
how industries from more than 20 categories from a variety of foreign countries have effectively overcome
similar obstacles.
ADDITIONAL HELP AND INFORMATION
Appendix E of this compendium contains a comprehensive bibliography listing by industrial category the
sources of all case studies included in this compendium. Compendium users may find this bibliography useful.
Also, EPA established the Pollution Prevention Information Clearinghouse (PPIC) in 1988 to improve and
encourage the transfer of pollution prevention and recycling information. As mentioned earlier, all of the case
studies in this compendium have been put into the PPIC (and the ICPIC, see below). The PPIC, however, is
also a free clearinghouse service containing technical, policy, programmatic, legislative, and financial
information relating to pollution prevention and recycling. The Clearinghouse is available to the public and
attracts a varied group of users, including pollution prevention professionals from industry; Federal, State and
local governments; trade associations; research institutions; academia; public interest groups; and international
organizations. EPA encourages and welcomes industry to use the PPIC to obtain and exchange pollution
prevention information. The PPIC can be reached through the EPA Clearinghouse Hotline at (202) 260-1023.
As part of the PPIC, EPA has established an electronic component known as the Pollution Prevention
Information Exchange System (PIES). PIES is a computerized information dissemination and exchange service
containing both technical and policy information accessible without user fees (except the cost of a telephone
call). The system includes an interactive message center, announcements, a calendar of events, case studies,
program summaries, a directory of contacts, a subject-specific mini-exchange, an environmental education
bibliography, and an electronic bibliography of documents in PPIC. Assistance with PEES can be obtained
through the PIES Technical Support Hotline at (703) 821-4800.
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Through a cooperative agreement with the United Nations Environment Programme (UNEP), EPA has
helped establish the International Cleaner Production Information Clearinghouse (ICPIQ in Paris, France.
Similar in scope and content to the PPIC, the ICPIC works in close cooperation with its U.S. counterpart. The
two clearinghouses are electronically linked and regularly share information. Together, these two programs (as
described in more detail in Appendix A) form a truly international pollution prevention network.
For more information on pollution prevention, interested persons should contact PPIC, a free
nonregulatory service of EPA, by mail, telephone hotline, or personal computer using the addresses, phone
numbers, and guidance provided in Appendix A. EPA encourages any organization or person with access to
case studies that do not appear in this compendium to submit this information to the address listed in Appendix
A. The procedures for submitting pollution prevention case studies are provided in Appendix B.
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CASE STUDIES
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BATTERY
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***** DOCNO: 400-070-A-307*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Automation of battery plate manufacturing process reduces lead oxide dust
by 85% and wastewater by 98%.
Metallurgical Industry/ISIC 38
This audit of a manufacturer of battery plates suggests that the automation
of the mold filling stage, reduces waste generation. Battery plates are
placed manually in a fixed mold which is located in a sound-proof cabinet.
When the cabinet is closed, the mold is automatically filled with lead
powder. This process is quite different from the standard technology where
the battery plates are placed in mobile molds which are manually handled
and filled with lead oxide powder. These operations are conducted under
water spraying in order to reduce dust. Polluted air is extracted.
Lead oxide powder, water
Lead oxide dust; water containing lead dust
Aqueous, air
Calculated based on 230,000 battery plates produced per year
FF 1,500,000 (1979 figures)
FF 7,730,000 (1979 figures)
Not reported
FF 565,000 (1979 figures)
Material consumption is 2.4 tons of lead oxide and 2 m3 of water per 1,000
battery plates (versus 2.6 tons of lead oxide and 80 m3 of water per 1,000
battery plates with the standard technology).
Manufacture of 1,000 battery plates generates 110 g of lead oxide dust
(including 16 g of lead) and 2 m3 of water containing lead dust (versus 830
g of lead dust, 380 g of lead and 80 m3 of water in the standard
technology).
The quantity of water used is substantially reduced, improving reliability
and efficiency. Substantial improvement of working conditions: elimination
of one night shift; reduction of operator fatigue, and the noise level goes
down from 95 dB (standard technology) to 85 dB (low-waste technology).
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Lead Battery Plates by
Automatic Filling of Fixed Molds", Monograph ENV/WP.2/5/Add.70.
Metallurgical Industry, Battery Plates, Mold Filling, ISIC 3800, Lead
Oxide, Dust Recovery, Wastewater
2-1
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CEMENT PRODUCTS
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***** DOCNO: 400-03l-A-220 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Wastewater and residue recyucling by an asbestos-cement processor.
Manufacturing of non-metallic mineral products with the exception of
petroleum and coal derivatives/ISIC 3699
Ministere de 1'Environment et due Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard de General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The company manufactures asbestos-cement panels and pipes and recycles
the water used in the process. The asbestos and the cement are mixed in
water. The resulting mixture is placed on a cloth rolling at high speed, is
drained and forms a thin layer that serves as a base for the panels and
pipes. The water drained in both processes is decanted twice. The residue
from the first decanting is recycled; that from the second is also recycled
in the low pollution process, while it is discharged in the standard process.
Wastewater from asbestos-cement panels.
Pollution is mainly due to water that is discharged.
Water
(1980 Francs)
F 5,500,000
F 2.6/ton asbestos-cement
Not reported
Not reported
Not reported
Not reported
Residue discharge is reduced by 57%; wastewater production is nearly
eliminated.
Reduces volume of disposed residue, and reduces wastewater discharge.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recycling of Water from Manufacturing of
Asbestos/Cement Panels and Pipes", Monograph ENV/WP.2/5/Add.31.
Cement, Asbestos, ISIC 3699, Wastewater, Recycling
2-2
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***** Document No. 453-001-A-OOO *****
1.0 Headline: Cement kiln NOx and SOx emissions reduced by improved process control
2.0 SIC Code: SIC 3241, Cement, Hydraulic
3.0 Name and Location of Company:
Blue Circle Industries pic, Hope Works facility
4.0 Clean Technology Category
The technology was improved process control using a computer expert-system to run the cement kiln at
its optimum operating conditions to reduced SOx and NOx emissions and conserve energy.
5.0 Case Study Summary
5.1 Process and Waste Information: Blue Circle Industries manufactures Portland cement by blending
fuel, limestone, and clay to produce a clinker and then grinding with gypsum. The process must
be operated within a certain temperature range to generate a usable product, avoid coal wastage,
and minimize air pollution.
The LJNKman expert-system continuously monitors all the appropriate process variables, such as
the flue gas temperature, oxygen, NOx level and the power used to turn the two cement kilns. It
then adjusts the coal, air and feed rates on the basis of a model of the plant's behavior derived from
operational experience. This allows the plant to run much closer to its optimum conditions than
is possible under manual control. One significant novel feature of the instrumentation is the
measurement of the NOx level in the flue gas which gives valuable information on the temperature
in the firing zone.
5.2 Scale of Operation: No information provided.
5.3 Stage of Development: The technology is fully operational.
5.4 Level of Commercialization: The technology is commercially available.
5.5 Material/Energy Balances and Substitutions: The NOx level of around 500 ppm is typically reduced
to 200 ppm.
6.0 Economics*
All economic data is based on 1987 prices. It is assumed that the economic figures are based on purchase
and operation of two cement kilns.
6.1 Investment Costs: 203,000 English Pounds.
6.2 Operational and Maintenance Costs: Annual savings in coal is 500,000 English Pounds and annual
savings in grinding clinker is 430,000 English Pounds.
6.3 Payback Time: Payback time is 3 months.
2-3
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7.0 Cleaner Production Benefits
NOx and SOx emissions are reduced. The wastage of coal at high temperatures is avoided. Higher quality
clinker is produced. The clinker requires less energy to grind. The lining of the kilns has a longer life.
Economic savings in energy costs are realized.
8.0 Obstacles, Problems and/or Known Constraints
None identified.
9.0 Date Case Study Was Performed: 1987
10.0 Contacts and Citation
10.1 Type of Source Material: Government publication.
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p23.
10.3 Level of Detail of the Source Material: A simplified process flow diagram is provided. Equipment
suppliers and contact are provided.
10.4 Industry/Program Contact and Address: Mr. W. Henerson, Chief Electrical and Process Control
Engineer, Blue Circle Industries pic, Technical Services Centre, 305 London Road, Greenhithe,
Kent DA99JQ, England, telephone (0322) 843011.
10.5 Abstractor Name and Address: John Houlahah, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Cement kiln emissions, nitric oxides, sulfur oxides, NOx, SOx
11.2 Process type/waste source: Portland cement manufacture
11.3 Waste reduction technique: Process efficiency, expert system, continuous monitoring
11.4 Other keywords: expert system, United Kingdom, Portland cement, SIC 3241
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Cement Kiln Emissions, Nitric Oxides, Sulfur Oxides, NOx, SOx, Portland Cement Manufacture,
Process Efficiency, Expert System, Continuous Monitoring, United Kingdom, Portland Cement, SIC 3241
2-4
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Pollution and Waste Reduction by Improved Process Control in Cement Production
2.0 SIC/ISIC Code: 3241
3.0 Name and Location of Company:
PT Semen Cibinong, Indonesia
4.0 Clean Technology Category:
5.0 Case Study Summary:
5.1 Process and Waste Information: Cement is made by burning a fuel together with limestone, clay,
and shale, yielding a clinker that is then ground with gypsum to produce cement. The process is
carried out in large rotating kilns and is highly sensitive to operational fluctuations. The use of coal
as fuel increases the dust content of the exhaust gases which is removed with electrostatic
precipitators. Off-specification product or increased pollutant content in the exhaust is generated
as a result of improper process control.
5.2 Scale of Operation: The facility operates two 2,000 ton per day dry process kilns using a low
sulfur coal.
5.3 Stage of Development: PT Semen Cibinong is currently implementing its process control system
at its facility in Jakarta, Indonesia.
5.4 Level of Commercialization: The LINKman System for process control is currently available from
ABB LINKman Systems Ltd in Beckenham, Kent.
5.5 Material/Energy Balances and Substitutions: No quantitative figures are given, but the system
increases capacity by 9 percent. Also, the clinker produced requires less energy to grind, and there
is a 40 percent reduction in off-specification material and a 3 percent fuel savings.
6.0 Economics*
6.1 Investment Costs: The capital investment of this system is about US$375,000.
6.2 Operational and Maintenance Costs: The system provides a power and fuel savings of
approximately US$350,000.
6.3 Payback Time: Less than one year.
7,0 ' Pollution Prevention Benefits
The advantages of the system are that the wastage of coal at high temperatures is avoided, a higher quality
clinker is produced, the lining of the kiln has a longer operational life, and there are some reductions in
NOX and SOX emissions.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: Not Identified.
2-5
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10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Pollution and Waste Reduction by
Improved Process Control," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Ir Sugiharto, P T Semen Cibinong, Jl Let Jen M T
Ilaryono, Jakarta, Indonesia, Tel: +62 21 819 0808
Mr Robert Harrison, ABB LINKman Systems Ltd, County House, 221-241 Beckenham Road,
Beckenham, Kent, BR3 4UF, Tel: +44 81 778 1200
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Off-specification cement
11.2 Process Type/Waste Source: Cement manufacturing
11.3 Waste Reduction Techniques: Process control
11.4 Other Keywords:
11.5 Country Code:
12.0 Assumptions
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Off-specification Cement, Cement Manufacturing, Process Control
2-6
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CHEMICAL MANUFACTURING
Adhesive and Sealants Manufacturing
Inorganic Chemical Manufacturing
Organic Chemical Manufacturing
Miscellaneous Chemical
-------
-------
Adhesive and Sealants Manufacturing
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Water-Based Adhesives Replaces Organic-Solvents and Reduces Emissions to Atmosphere
2.0 SIC/ISIC Code:
3.0 Name and Location of Company:
Blueminster Ltd, Kent, United Kingdom
4.0 Clean Technology Category: This technology uses water-based adhesives, replacing the more common
organic solvent-based adhesives, for possible application in a wide variety of industries.
5.0 Case Study Summary:
5.1 Process and Waste Information: This technology is designed to replace organic-solvent based
adhesives with water-based adhesives. When solvent based adhesives are used, the solvent is
volatile and evaporates to the atmosphere contributing to air pollution or the solvent is removed by
high-energy drying and is recovered. Hot-melt organic adhesives do not use solvents, but are also
high energy consumers.
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: Various trials have been carried out and small scale production has
commenced.
5.4 Level of Commercialization: Not Discussed.
5.5 Material/Energy Balances and Substitutions: Not identified.
6.0 Economics*
6.1 Investment Costs: Not identified.
6.2 Operational and Maintenance Costs: Not identified.
6.3 Payback Time: • Not identified.
7.0 Pollution Prevention Benefits
Water-based adhesives are non-toxic, do not pollute the atmosphere or water systems, do not require
special handling, and are not a fire hazard. Also, solvent-based adhesives need three to five times the
drying energy of water-based adhesives. Water-based adhesives need no special solvent recovery system
or explosion proof equipment. Water-based adhesives can generate higher levels of adhesion through
penetration of absorbent substrates, such as cellulose, and will allow more time for the precise positioning
of adherents. Water-based adhesives are particularly suitable for food packaging.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: Not Identified
2-7
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10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "New Product: Water-Based Adhesives,"
1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Trevor Jones, Managing Director, Blueminster Ltd, Unit
17 Chaucer Business Park, Kemsing Sevenoaks, Kent TN15 6PJ, Tel: +44 732 61858
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation,
7600A Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Air emissions
11.2 Process Type/Waste Source: Water-based adhesives
11.3 Waste Reduction Techniques: Material substitution
11.4 Other Keywords:
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600A Leesburg Pike, Falls
Church, Virginia, 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Air Emissions, Water-based Adhesives, Material Substitution
2-8
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Inorganic Chemical Manufacturing
***** DOCNO: 400-074-A-248 *****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Agitator reactor used to recover phosphorous and reduce energy
consumption.
Industrial Chemical Manufacturing/ISIC 3511
Phosphorous contained in the by-product sludge from phosphorous
production is converted to sodium phosphinate via alkaline digestion in an
agitator reactor. The digestion suspension product contains contaminants
from the sludge and is, therefore, filtered prior to further processing.
Subsequent processing includes neutralization, evaporation, crystallization,
centrifugation, and drying. This yields the sodium phosphinate final
product, along with some CaHPO. The liquid resulting from the
centrifugation is recycled to the process. Phosphine and hydrogen off-gases
from the reaction are utilized in the production of phosphoric acid
(combustion to H3PO4, mist absorption in circulating phosphoric acid).
Phosphorous sludge, acetylene-lime hydrate, sodium hydroxide,
hydrochloric acid, nitrogen, steam, electric power, water.
With the low pollution technique there is a discharge of 340 kg PH3
(intermediate product), 77 kg NaCl, 2 kg sodium-phosphinate dust and 5 kg
filter cake.
Water, air, solid
Low, relative to conventional technology, due to the use of common steel
over stainless steel.
50% reduction in energy consumption over conventional technology.
Elimination of heavy corrosion costs.
Installation can be amortized over less than three years.
Not reported
Phosphine gas emitted from reactor is utilized in phosphorous acid plant.
Not reported
Currently, 30% of the applied phosphorous is emitted into waste water in
an elementary form. 10% is emitted into waste water in the form of P2OS.
Low-waste technology recovers nearly all the applied phosphorous, yielding
sodium phosphinate for use in electrolytic nickeling, and a non-toxic filter
cake.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Sodium Phosphate Made From Phosphorous
Sludge", Monograph ENV/WP.2/5/Add74.
Phosphorous, Sludge, ISIC 3511
2-9
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***** DOCNO: 400-040-A-229 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Debufabler used to extract nitrates from water vapor.
Chemical Industry and Manufacturing of Chemical Products, Petroleum and
Coal Derivatives and Rubber and Plastic Products/ISIC 3512
Ministere de PEnvironnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The company produces ammonium nitrate with direct verification of the
reaction and debubbling of the water vapor extracted. In the low pollution
technique, the verification of the reaction of the two basic elements
(concentrated nitric acid and ammonia) is carried out through the pH
analysis of the residual water collected at the end of the process. This
water was originally contained in the nitric acid and was obtained by
evaporation of the ammonium nitrate solution followed by condensation.
In the low pollution technique, the ammonium nitrate laden water vapor
passes through a debubbler before condensation which limits the nitrate
bubbles carried by the vapor.
Ammonium nitrate, nitric acid
Wastewater containing ammonium, nitrogen, and nitric acid
Aqueous
F 300,000
Not reported
84
Not reported
Ammonium nitrate waste reduced by 93%.
Material consumption is reduced in the low pollution technique by just
under 2 per cent. Energy consumption, generally low, is more or less the
same in both techniques. This technique allows closer verification of the
chemical reactions that take place during production and thus gives a better
material yield and less pollution. This principle should be extended to other
procedures in the chemical sector.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Ammonium Nitrate with
Continuous Control of the Reaction and Degassing of the Resulting Water
Vapors", Monograph ENV/WP.2/5/Add.40.
Ammonium Nitrate, Reaction Verification, Debubbling, ISIC 3512
2-10
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***** DOCNO: 400-112-A-271*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Waste silica recovered during aluminum fluoride production is marketable
product.
Manufacture of Basic Industrial Chemicals Except Fertilizer/SIC 28
The low waste technology is for the production of aluminum fluoride with
utilization of waste silica. There are no significant changes in the
production of the aluminum fluoride. The use of waste silica permits the
manufacture of a marketable product to be used as a filler in rubber
compounds. The steps of the process include:
- Dissolution of the waste inactive silica by treating it with an ammonium
fluoride solution.
- Separation of ammonium cryolite by filtration, to be used in ammonium
fluoride production.
- Precipitation of active silica by treating the ammonium fluosilicate
solution with ammonia (gas) or ammonia water.
- Separation and washing of active silica on the press filter.
- Evaporation of ammonium fluoride solution.
- Drying and packaging of active silica.
Silicon (inactive) from aluminum fluoride production (23% SiOj) - 4,384
kg/metric ton output; B(SiF6 (100 %) - 269 kg; NH3 - 327 kg; process
water - 2,330 kg; industrial water - 150 m3.
Residual gases (50 mVton) from the calcination of active silica, containing
less than 10 mg/m3 F, are washed and passed into the atmosphere. Process
waters and waste water from equipment washing are recycled to the process
for washing active silica cake.
Gaseous, liquid
(Rubles per metric ton)
9,500 thousand rubles
330 rubles/metric ton
Not reported
120 rubles/metric ton gross profit on active silica filler.
Not reported
Five percent savings from depreciation charges on pollution control
measures attributed to the elimination of the waste silica disposal, in
addition to disposal costs.
Elimination of silica disposal in a landfill site or storage pond, by creating
a profitable use for this waste by-product.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Aluminum Fluoride with the
Utilization of Waste Silica" Monograph ENV/WP.2/5/Addll2.
Silica, Precipitation, Solid Waste Recovery, Fillers, Aluminum Fluoride,
SIC 28
2-11
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***** DOCNO: 400-092-A-318*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST*
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Titanium anodes and crystallization are used to recover chlorate, reduce
energy needs, and eliminate graphite sludge.
Manufacture of Basic Industrial Chemicals Except Fertilizer/ISIC 3511
Liquors containing soda chlorate and sodium chloride are injected into
electrolyzers which transform chloride into chlorate with titanium anodes.
The resulting liquors are then sent to a crystallizing pond where part of the
chlorate is recovered. The remaining part is returned to the electrolyzers
after addition of sodium chloride.
Sodium chloride, electrical energy, titanium anodes
None
Not applicable
9,000,000 francs (1978)
601 francs/ton of product (1980)
Not reported
191 francs/ton in electrical energy, which is offset by increased cost of 100
francs/ton for titanium anodes.
Reduced energy requirements.
Conventional technology uses graphite anodes which requires recovery and
rejection of graphite powder sludge
The standard technique involves filtration of the liquors prior to
crystallization because the graphite anodes are gradually consumed (at a rate
of 6 kg/ton). Consequently, waste disposal of graphite sludge is required.
Additionally, energy consumption is reduced with the low waste technology.
Titanium anodes may be used wherever alkaline chlorates are produced via
electrolysis.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Manufacturing of Soda Chlorate by
Electrolysis of Sodium Chloride with Graphite Anodes", Monograph
ENVAVP.2/5/Add.92.
Electrolytic Recovery, Chlorate, ISIC 3511
2-12
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***** DOCNO: 400-123-A-330*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATING/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Low waste technology process used in producing hydrogen fluoride acid
reduces volume of synthetic anhydrite produced by 85%.
Manufacture of Basic Industrial Chemicals Except Fertilizers/ISIC 3511
Synthetic anhydrite (calcium sulphate), produced from the production of
hydrogen fluoride acid, is prepared to form a standardized anhydrite binder
for use in floor construction in buildings. Part of the anhydrite produced
is applied in the cement industry as a setting regulator. Conventional
method is to dispose of the anhydrite. The low waste technology process
involves an additional step of milling to reduce the grain size, requiring
additional classifiers, mills, and bagging apparatus.
Ca(OH)2 - 50 kg/ton anhydrite, ventilated paper sacks - 6.25 kg, activator-
15 kg, electricity - 97.2 Ml, compressed air (0.3 MPa) - 220 m3
Anhydrite waste
Solid
4,000,000 Marks
80% of capital investment
Not reported
Investment costs are increased by 1,700,000 Marks, operating costs are
reduced by 20%. Savings are realized through reduced disposal costs and
sales of anhydrite.
None
To-date, 60 % of the anhydrite has been produced as anhydrite binder, 25 %
as setting regulator, and 15% was disposed of as a waste (6 kt/a per 10 kt/a
HF).
The volume of solid waste requiring disposal from production of HF is
reduced by 85%. Operating costs are reduced by 20% due to
transportation and disposal costs, and a profitable product is produced that
offers advantages in the construction of floors over other binding agents
used for the same purpose.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, Monograph "Use of Anhydrite Formed in
the Hydrogen Fluoride Production Process" ENV/WP.2/5/Add.l23.
Solid Waste Recovery, Hydrofluoric Acid, Anhydrite, ISIC 3511
2-13
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*****DOCNO: 450-01 l-A-001*****
1.0 Headline: New sodium chlorate factory triples production and employs source reduction techniques to
avoid treatment costs
2.0
SIC: 2812
3.0 Name and Location of Company
La Societe Quenord, Magog, Quebec, Canada
4.0 Clean Technology Category
5.0 Case Study Summary
5.1 Process and Waste Information: Quenord is the largest manufacturer of sodium chlorate in the
world. Their product is principally used in the fabrication of chlorine for use in the pulp and paper
industry. In 1985, Quenord built a new factory that tripled its production and because of reduction
techniques, its effluent was reduced to almost nothing. The company decided the most effective
modifications could be made regarding the refrigeration waters which cool the liquor before their
return to electrolytic cells. They used a closed circuit and an open circuit to recover calorific
energy (about 22 megawatts), to reduce the amount of water used as much as possible, and to avoid
contaminating the waters to eliminate the need for treatment.
The company also used other preventative measures to reduce the amount of pollutants they
generate. To reduce the volume of sludge to be disposed, they used table salt and a filter press.
To eliminate the separation of their existing anodes, they used metallic anodes. To eliminate the
contamination of condensation waters, the company used a surface condenser rather than a
barometric condenser. The company used a demisting device that allowed condensate to be
recycled. To limit losses of primary material and finished products, a series of pits and pumps
returned the material to production and any dust generated was sprayed to wet it. To capture runoff
or accidental releases of primary materials, the company used angled barriers and drainage channels
around the reservoir and also used good insulation around the buildings and equipment. To
eliminate hot purge waters, the company employed an electric heating system. To reduce the risk
of chromium release to the environment, the company produced chlorate crystals that were already
washed and dried.
By using source reduction, the company saved the $600,000 cost of installing a treatment system.
They were able to completely recycle refrigeration waters through closed circuit instead of treating
them, they were able to recover energy that normally would have been lost by using an open
circuit. This measure saved the company $500,000/year in production costs. Using metallic
anodes, eliminating graphite sludge and increasing the output of electricity at a more efficient rate
allows the company to save $2,000,000/year.
5.2 Scale of Operation: The company produces approximately 95,000 tons of sodium chlorate/year.
5.3 Stage of Development: This technology was fully implemented at the time of the case study.
5.4 Level of Commercialization: This technology was commercially available at the time of this case
study.
2-14
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5.5 Material/Energy Balances and Substitutions
Effluent
Standards
Total Flow [m3/d] 715 —
Free Chlorine [g/m3] 0.05
NaClO(3) [g/m3] 5.5
[kg/d] 4.0
Total Chrome [g/m3] 0.01 1.0
*S.S. [g/m3] 6.0 30
S.D. [g/m3] 200-351 3000
DCO[g/m3] 26 30
pH - 7-8.5 5.5-9.5
* Suspended Solids
6.0 Economics*
6.1 Investment Costs: The company spent $900,000 total. Use of the techniques saved $600,000 in
the cost of a treatment system.
6.2 Operational and Maintenance Costs: Operational and maintenance costs of the program were not
provided. However, $500,000/year were saved in production costs and $2,000,000/year were saved
in energy costs.
6.3. Payback Time: The payback time of this operation was approximately 4 months.
It is assumed that costs were reported in Canadian dollars.
7.0 Cleaner Production Benefits: As a result of using source reduction techniques, the company virtually
eliminated all effluents except for the release of disinfection waters from the refrigeration process. They
periodically sell condensate from their crystallization system and they save $600,000/year in treatment
costs, $500,000/year in production costs, and $2,000,000/year in energy costs.
8.0 Obstacles, Problems and/or Known Constraints: Not Available
9.0 Date Case Study Was Performed: The pollution prevention measure were initiated in 1985.
10.0 Contacts and Citations
10.1 Type of Source Material: Report
10.2 Citation: Secteur Chimie Inorganique. Technologies Propres. Production du Chlorate de Sodium.
Gouvernement du Quebec, Ministere de 1'Environnement, Gestion et Assainissement des Eaux,
Revised June 1988. Source document is in French.
10.3 Level of Detail of the Source Material: > Additional detail is available regarding the actual
refrigeration process and the open and closed circuits. Greater explanation is also given regarding
other preventative measures.
2-15
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10.4 Industry/Program Contact and Address: Regional offices, addresses and phone numbers are given
on the back of the report.
10.5 Abstractor Name and Address: Blair M. Raber, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, VA, 22043.
11.0 Keywords
11.1 Waste Type: Wastewater, refrigeration waters.
11.2 Process Type/Waste Source: Basic Wastewaters, Chlorine, Industrial Inorganic Chemical,
Inorganic Chemicals, Refrigerant, Sodium Chlorate.
11.3 Waste Reduction Technique: Source Reduction, Crystallization, Energy Recovery, Equipment
Modification, Insulation, Process Redesign, Refrigeration and Heating Equipment, Volume
Reduction, Wastewater Reduction.
11.4 Other Keywords: Canada, Dust, Increased Productivity, Increased Efficiency.
(*) Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Refrigeration Waters, Basic Wastewaters, Chlorine, Industrial Inorganic Chemical,
Inorganic Chemicals, Refrigerant, Sodium Chlorate, Source Reduction, Crystallization, Energy Recovery,
Equipment Modification, Insulation, Process Redesign, Refrigeration and Heating Equipment, Volume Reduction,
Wastewater Reduction, Canada, Dust, Increased Productivity, Increased Efficiency
2-16
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Organic Chemical Manufacturing
***** DOCNO: 400-033-A-222 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Use of water to neutralize alkylates is eliminated during the manufacture of
ethylbenzene.
Chemical Industry and Manufacturing of Chemical Products, Petroleum and
Coal Derivatives and Plastic and Rubber Products/ISIC 3540
Ministere de 1'Environnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
Dry neutralization of the alkylates resulting from the manufacturing of
ethylbenzene is used instead of wet neutralization. In the low pollution'
technique, elimination of the salts and impurities from the ethylbenzene
solution obtained by an ethylene reaction with benzene is carried out without
water.
The solution is neutralized in ammonia, then flocculated and decanted. The
sediment is centrifuged and vacuum dried. The solid residue obtained can
be used to manufacture mixed fertilizers.
Raw ethylbenzene product containing salts and impurities.
The low pollution technique does not produce wastes because solid residues
are used in other applications (fertilizer manufacturing). Wastes produced
in the standard technique are salts (ammonium and aluminum chloride),
aluminum hydroxide, and hydrocarbons dissolved in water.
Liquid (ethylbenzene)
(1978 Francs)
F 5.25 million
Not reported
Not reported
Not reported
Not reported
Wastes discharged to the environment are eliminated.
The low pollution technique does not require water (as opposed to the
standard technique, which requires 1.5 m3 per ton of ethylbenzene).
The amount of other raw materials used is identical (0.27 ton of ethylene,
0.745 ton of benzene, 7 kg of catalysts, 3.5 kg of ammonia per ton
ethylbenzene). The output should however, be improved by 1 to 2 per cent
in the low pollution process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Dry-Phase Neutralization of Alkylates
Generated in the Production of Styrene", Monograph ENV/WP.2/5/Add.33.
Ethylbenzene, Neutralization, Purification, ISIC 3540
2-17
-------
***** DOCNO: 400-093-A-319*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Recycling of desalination water in hydrazine production process reduces
wastewater generation by over 90%.
Manufacture of Basic Industrial Chemicals Except Fertilizer/ISIC 3511
Produce hydrazine hydrate by oxidizing ammonia with hydrogen peroxide,
in the presence of other chemicals. After several processes, these chemicals
are recovered and recycled upstream. In addition to hydrazine hydrate,
other mineral residues are recovered for use in cement works, and heavy
tars are burned away.
'Ammonia, hydrogen peroxide, water, energy
Mineral residues (6.7 kg/ton), tar (13.3 kg/ton)
Wastewater
52,000,000 francs (15 tons of hydrazine hydrate produced per day)
40% lower than standard technique
Not reported
7,000,000 francs savings in original investment, 40% lower operating costs.
14 m3 water required for standard techniques compared to 1.6 m3 for
low-waste technique, energy requirements are reduced from 570 MG to 220
MG.
27 mVton of desalination water are rejected in standard techniques
(containing 2.4 tons of chloride ions for one ton of product) compared to
negligible waste production in low waste technology.
The oxidation of ammonia with hydrogen peroxide reduces wastewater
generation and investment and operating costs. Mineral residues and other
chemicals are also recovered.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Hydrazine Hydrate through
Oxidizing Ammonia with Bleach", Monograph ENV/WP.2/5/Add.93.
Inorganic Chemicals, Wastewater, Oxidation, Desalination, Hydrazine
Hydrate, Raw Material Substitution, Recovery, ISIC 3511
2-18
-------
***** DOCNO: 400-034-A-223 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:.
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Chemical Industry and Manufacturing of Chemical Products, Petroleum and
Coal Derivatives and Plastic and Rubber Products/ISIC 3511
Ministere de 1'Environnement et du Cadre de Vie
Direction de a! Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
Cracked hydrogen containing 20 to 22 per cent of carbon dioxide is washed
in a solution of potassium carbonate. The solution containing carbon
dioxide is heated in an exchanger where the input cracked gas yields heat.
It is then treated in a column containing nitrogen and it is regenerated.
Wastes are made up of carbon dioxide and nitrogen.
Cracked hydrogen and nitrogen
The wastes produced by the low pollution processes (including washing and
ammonia synthesis) contain 0.03 kg of ammonia in solution per ton of
ammonia produced.
Hydrogen gas
Not reported
Not reported
Not reported
Not reported
Eliminates ammonia discharge.
The low pollution technique allows substantial energy saving through steam
saving.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Hydrogen Washing by Potassium Carbonate
in Ammonia Production", Monograph ENV/WP.2/5/Add.34.
Ammonia, Hydrogen, ISIC 3511
2-19
-------
DOCNO: 400-116-A-329*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATING/MAiNTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Recycling and sorption of CC13F and TDI generated during the production
of polyurethane (PUR) block soft foam.
Manufacture of Synthetic Resins, Plastic Materials and Man-made Fibers
Except Glass/ISIC 3513
The technology involves the sorption and recycling of harmful materials in
process gases generated during the production of polyurethane (PUR) block
soft foam. Activated charcoal is used for removing CC13F and TDI which
are emitted with the exhaust air during the conventional production process.
Adsorption of TDI is an irreversible process, which eliminates the option
of recovering the TDI. The CC13F, however, is recovered through
regeneration of the charcoal bed with hot steam.
Steam, electric power, cooling water, activated charcoal, exhaust stream
CC13F in purified exhaust air (<20 mg/m3), CC13F in condensed aqueous
phase (<0.01% by weight), TDI converted to innocuous polyurea on
activated charcoal (no longer detectable).
Gaseous, water, solid
700,000 DM (1983 for plant capacity of 30,000 m3 exhaust air per hour)
557 DM/ton of recovered CC13F
30
The recovery process is an addition to the process.
1443 DM/ton of recovered CC13F
CC13F emitted is <20 mg/m3 compared to 0-50 g/m3 without the recovery
process (regulatory level is 300 mg/m3), and TDI is now captured in the
charcoal bed compared to emissions of 0-20 mg/m3 without recovery
(regulatory level is 20 mg/m3).
This sorption and recovery process achieves extremely low CC13F emissions
from the polyurethane foam manufacturing process and TDI emissions
below the detection limit. Additionally, CC13F resources are recovered with
this process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Sorption and Recycling of Harmful
Materials During the Production of Polyurethane (PUR) Block Soft Foam",
Monograph ENV/WP.2/5/Add.ll7.
Gas Collection, Carbon Adsorption, Polyurethane, ISIC 3513
2-22
-------
***** DOCNO: 400-081-A-313*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Modification to the dehydration stage of chloral manufacturing reduces
wastewater generation by 60%.
Manufacture of Industrial Chemicals/ISIC 351.
This audit presents the modification to the dehydration stage of the chloral
manufacturing. Chloral synthesis is achieved by ethanol and chlorine
reaction. The resulting product which is approximately 80% chloral is then
dehydrated using a solvent. The conventional process uses concentrated
sulfuric acid (oleum) for dehydration. The sulfuric acid in the conventional
process is separated after the distillation step and then rejected. The solvent
in the low-pollution process is recycled after distillation. The chloral is
separated from chlorinated by-products which are used by the plant, and
from water which is slightly acidic.
Solvent, chloral, ethanol, chlorine
Polluting wastes resulting from the low-pollution technique consist of
slightly acidic water. In the case of the conventional technique, sulfuric
acid is rejected after dehydration.
Aqueous
FF 8,500,000 (1974 figures)
FF 3,270 per ton of product (1979 figures)
Not reported
FF 90 per ton of product (1979 figures)
Both techniques require 445 kg of ethanol and 2,100 kg of chlorine for the
production of one ton of chloral. In addition, dehydration requires 6 kg of
solvent (versus 600 kg of oleum for the conventional technique).
The low-pollution process generates 140 liters (versus 360 liters) of slightly
acidic water which is neutralized and discharged.
Because it does not use sulfuric acid, the low-pollution technology enhances
safety conditions in manufacturing plants.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Manufacturing of Chloral: Dehydration by
Means of a Solvent", Monograph ENV/WP.2/5/Add.81.
Chlorine, Solvent, Organic Chemical, Ethanol, Chloral, ISIC 351
2-23
-------
Miscellaneous Chemical
***** Doc # 501-016-A-OOO *****
1.0 Headline: Pollutants from discharge waters eliminated by new separation step in making caprolactam from
toluene.
2.0 SIC Code: SIC 2869, Industrial organic chemicals, not elsewhere classified
3.0 Name and Location of Company:
Societa Chimica Dauna
Manfredonia, Italy
4.0 Clean Technology Category:
A new separation step meshed into an established process for making caprolactam from toluene forms no
ammonium sulfate byproduct and eliminates pollutants from discharge waters.
5.0 Case Study Summary
5.1 Process and Waste Information: In the conventional process, ammonia neutralizes the
caprolactam-sulfuric acid composite to produce crystals of ammonium sulfate. Caprolactam oil
floating on top of the mother liquor is decanted, and extracted first by toluene and then by water.
The water raffinate draws off the impurities formed during nitrosation and is discarded.
The technology involves a new separation step. Caprolactam is separated from the sulfuric acid
in which it is dissolved during reaction by extraction with an alkylphenol solvent. No ammonia is
used, and thus no ammonium sulfate forms. The remaining sulfuric acid is thermally cracked,
destroying impurities while forming sulfur dioxide for recycle.
5.2 Scale of Operation: Plant capacity is 80,000 metric ton/year.
5.3 Stage of Development: The technology is implemented.
5.4 Level of Commercialization: The technology is commercially available.
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
This technology eliminates the generation of ammonium sulfate byproduct and eliminates an aqueous
wastestream. The composition of the aqueous wastestream was not identified.
2-24
_
-------
8.0 Obstacles, Problems and/or Known Constraints
Increased energy is used in this new process because of the cracking step.
9.0 Date Case Study Was Performed
July 1974
10.0 Contacts and Citation
10.1 Type of Source Material: Book
10.2 Citation: Process Technology and Flowsheets, articles which appeared in Chemical Engineering
over the last five years. V. Cavaseno and Staff of Chemical Engineering eds., McGraw-Hill, NY,
NY, 1979. Caprolactam from Toluene Without Ammonium Sulfate, Andrew Heath. Pg. 137.
10.3 Level of Detail of the Source Material: Detail of each process step and a process flowsheet are
available in the source document.
10.4 Industry/Program Contact and Address: Unknown
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Ammonium sulfate, wastewater
11.2 Process type/waste source: Caprolactam manufacture
11.3 Waste reduction technique: Process modification
11.4 Other keywords: Industrial organic chemicals, solvent extraction, SIC 2869
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors. •
Keywords: Ammonium Sulfate, Wastewater, Caprolactam Manufacture, Process Modification, Industrial Organic
Chemicals, Solvent Extraction, SIC 2869
2-25
-------
-------
ELECTRICAL EQUIPMENT
-------
-------
***** DOCNO: 450-003-A-345*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Powder-coating painting process used for appliances allows for recycling of
paint powder and hot air thereby reducing hazardous waste generated.
Electric and Electronic Machinery/SIC 36
W. C. Woods Company, Ltd.
Guelph, Ontario
A powder-coating process for painting freezers uses a specially formulated
fusible paint powder which is applied to the appliance in an enclosed spray
booth. The appliance is then heat-cured in an oven to fuse the paint to the
surface of the appliance. This technique eliminates solvent emissions, and
the paint can be easily recycled compared to conventional liquid paints. No
paint sludge is produced and no large volumes of wastewater are generated.
Powder coatings, hot air
Powder coatings
Solid
Not reported
Lower than a conventional paint line because less material and labor is
required.
Not reported
Quantities not reported.
Hot air from the oven is recycled since it does not contain solvent
emissions. As a result, overall energy required is lower.
Eliminated paint sludge and wastewater
The powder-coating spray booth allows for a more efficient process,
requiring less materials and labor, and generating less hazardous waste.
The paint powder and the hot air can be recycled.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects",
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 35.
Paint, Recycle, Heat Recovery, Process Change, SIC 36
2-26
-------
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
4.0
5.0
6.0
Headline: Substitution of metal working fluid promotes less need for organic solvent degreasing. Substitution
of solvent-based paint with powdered paints further minimi7.es organic solvent emissions.
SIC/ISIC Code: SIC 3648, Lighting Equipment, NEC
Name & Location of Company: Gamkonst AB, P.O. Box 305, S-261, 23 Landskrona, Sweden.
Clean Technology Category: This clean technology scheme involves the substitution of mineral oil-based
metalworking fluids with a vegetable-oil replacement, the switch from trichloroethylene degreasing to an
alkaline, water-based detergent system, and the utilization of powdered paints instead of solvent-based liquid
paints. Program reduced trichloroethylene and mineral solvent emissions.
Case Study Summary:
5.1 Process and Waste Information: Fixture manufacturing facility utilized a mineral oil-based cutting
fluid for metalworking. Manufactured components were then degreased using trichloroethylene
solvent. Solvent-based paints were utilized in the final, finishing of parts.
The new program relies upon the use of a vegetable oil-based cutting fluid for metalworking
operations. Substitution with this material allows parts degreasing with an alkaline detergent
solution. Use of powdered paints results in reduced organic solvent vapor emissions and reduced
operating costs.
5.2 Scale of Operation: 400,000 pieces/year
5.3 Stage of Development: Clean technology is fully implemented.
5.4 Level of Commercialization: Clean technologies are fully commercialized.
5.5 Material Balances:
Material Category
Waste Generation:
Quantity Before Quantity After
Trichloroethylene vapor
Mineral Solvent vapor
N/A 5 tons/year less
than before
N/A 30 tons/year less
than before
.Economics*:
6.1
Investment Costs: Investment for system for powdered painting was $383,000. No other
investment costs provided.
2-27
-------
6.2 Operational & Maintenance Costs: Vegetable oil use saves $5,000/year over mineral oil.
Trichloroethylene: trichloroethylene use would have required investment of $50,000 for recycling
unit plus additional $9,000/year operating expenses. Previous cost was $10,000/year with
$500,000/year operating costs.
Operating costs for powder painting is $415,800/year less than for solvent-based painting. Initial
investment for painting system was $383,000.
6.3 Payback Time: Payback for painting system changeover investment was less than 1 year. Payback
period calculation for new powder painting system is based upon provided annual cost savings
estimate.
7.0 Cleaner Production Benefits: New processes do away with the need for trichloroethylene degreasing;
organic solvent emissions are minimized and costs associated with solvent purchases and waste disposal are
greatly reduced. Cutting fluid costs are reduced. Workplace exposure to solvents is prevented. In
addition, the new system facilitates compliance with air pollution standards.
8.0 Obstacles, Problems & Constraints: Not reported
9.0 Date Study Performed: Clean technology process changeover started in 1987 and was completed in July,
1989.
10.0 Contacts & Citation:
10.1 Type of Source Material: Not specified
10.2 Citation: Siljebratt, Lars et al; Forebyggande miljoskyddssstrategi och miljoanpassad teknik i
Landskrona, etapp 2. ISSN 0281-5753
10.3 Level of Detail: Not reported
10.4 Industry/Program Contact: Egon Konradis
10.5 Abstractor Name: UNEP Working Group On (Halogenated) Solvents. Reformatted by Douglas
Martin, Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, VA
22043.
11.0 Keywords:
11.1 Waste Type: Organic vapors, trichloroethylene, mineral oil
11.2 Process Type: SIC 3648, lighting fixtures, painting, degreasing
11.3 Waste Reduction Technique: Material substitution, powder process
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Organic Vapor, Trichloroethylene, Mineral Oil, SIC 3648, Lighting Fixtures, Painting, Degreasing,
Material Substitution, Powder Process
2-28
-------
-------
ELECTROPLATING
-------
-------
***** DOCNO: 400-100-A-323*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATiON/PAGE:
KEYWORDS:
Copper-plating rinse water is recycled via electrodialysis allowing for
recovery of copper ions for reuse while significantly reducing volume of
wastes produced.
Manufacture of Fabricated Metal Products, Machinery and Equipment/ ISIC
38
Rinse water from the copper-plating of parts is recycled via electrodialysis.
This allows for recovery of the copper ions for reuse in the copper plating
process, and recycling of purified rinse water. Conventional technology
involves recycling of rinse water by removal of the ions with ion-exchange
resins, resulting in the production of toxic effluents from the resin
regeneration.
Electrical energy, copper
Metal hydroxide mud resulting from detoxication of rinse waters containing
copper and sodium cyanide
Sludge
463,000 francs (1980 franc)
110,000 franc reduction in detoxication cost
Not reported
110,000 franc reduction in detoxication cost
Reduction in copper and energy requirements
Volume of metal hydroxide mud is reduced by 90%. Waste waters
contained 340 kg of copper compared to 3400 kg in standard technique, and
375 kg of sodium cyanide 'compared to 37SO kg
This low waste technology significantly reduces the volume of wastes
produced from copper-plating while reducing the raw material and energy
requirements for the process. The technique may be applied to the
electroplating of other metals.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Copper-plating of Parts Followed by
Electrodialysis: Recovery of Copper Contained in Rinsing Water",
Monograph ENV/WP.2/5/Add. 100
Metal, Electroplating, Recovery, Rinsewater, Recycling, Electrodialysis,
ISIC 38
2-29
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***** Document No. 453-001-A-OOO *****
1.0 Headline: Copper recovery from printed circuit board etchant using electrolysis improves product quality
and eliminates copper waste disposal costs and handling of hazardous chemicals
2.0
3.0
4.0
5.0
6.0
SIC Code: 3672, Printed Circuit Boards
Name and Location of Company:
Finishing Services Ltd.
Wobura Road Industrial Estate
Xempston,
Bedfordshire MK42-7BU, England
Clean Technology Category
The technology involves reclamation of copper using electrolytic recovery of a PVC-based membrane.
Case Study Summary
5.1 Process and Waste Information: Finishing Services Ltd. manufactures printed circuit boards In
making printed circuits, unwanted copper foil is etched away by an acid solution of cupric chloride
Dissolved copper reduces the effectiveness of the solution. The solution is typically regenerated
by oxidizing the cuprous ion with acidified hydrogen peroxide. The volume of solution however
increases steadily and the surplus liquor must be stored. The copper in the surplus liquor is
precipitated as copper oxide and landfilled. The new technology uses electrolytic recovery with a
PyC-based membrane which allows the passage of hydrogen and chloride ions but not the copper
The copper is transferred to the cathode and recovered as pure flakes.
5.2 Scale of Operation: A staff of 55 people are employed in England.
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: The technology is commercially available from Finishing Services
Ltd. °
5.5 Material/Energy Balances and Substitutions: Copper Recovery is 11 te/year.
Economics*
6.1 Investment Costs: Investment costs are 55,000 English Pounds.
6.2 Operational and Maintenance Costs: Annual cost savings (in English Pounds)reported as:
Cost Savings
6.3
Materials
Savings in disposal costs
Less extra costs
Total
Payback Time: 2 years
22,000
6,000
1,000
27,000
2-30
-------
7.0 Cleaner Production Benefits
The quality of the printed circuit boards is improved. Disposal costs for copper are virtually eliminated.
The etching solution is maintained at its optimum composition. Copper is recovered in a high value form,
and there are no hazardous chemicals to be handled.
8.0 Obstacles, Problems and/or Known Constraints
None identified.
9.0 Date Case Study Was Performed: Unknown
10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p2.
10.3 Level of Detail of the Source Material: Simple diagram of process provided.
10.4 Industry/Program Contact and Address: Mr. Gareth Weed, Technical Manager, Finishing Services
Ltd., Wobum Road Industrial Estate, Kempston, Bedfordshire MK42 7BU, Telephone (0234)
857004
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Etchant liquors
11.2 Process type/waste source: Electronic equipment, United Kingdom
11.3 Waste reduction technique: Copper recovery, solid waste recovery, electrolytic recovery
11.4 Other keywords: SIC 3672
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Etchant Liquors, Electronic Equipment, United Kingdom, Copper Recovery, Solid Waste Recovery,
Electrolytic Recovery, SIC 3672
2-31
-------
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: An experimental project using an electrowinning cell and ion exchange unit minimizes water
usage and hazardous waste
2.0 SIC Code: SIC 3471, Electroplating, Plating, Polishing, Anodizing, and Coloring
3.0 Name & Location of Company
Kinetico Engineering Systems, Inc.
Newbury, Ohio
4.0 Clean Technology Category
Technology Principle: This experimental technology uses an electrowinning cell and ion exchange system
to recover copper and reduce water usage.
5.0 Case Study Summary
5.1 Process and Waste Information: The line on which the experiment was undertaken is composed
of a bath for bright acid copper plating, followed by a "dead" rinse and two rinses in counterflow.
Nothing about pretreatment is mentioned in the source document. The dead rinse consists of a tank
of 1500 gallons used to replenish the volume lost from the plating bath. The first running rinse,
also 1500 gallons, overflowed to the waste treatment facility. The second running of 3000 gallons,
was fed with 4 gallons of city water per minute. In the first stage of the project, an electrowinning
system was introduced in a circulating loop with the dead rinse resulting in reduction in the copper
content and in drag-out of copper into the running tanks. The electrowinning cell design consisted
of a tank using up to 50 square feet of cathode material and 48 square feet of insoluble anode. A
300 Amp, six volt rectifier powered the cell. Current densities could be varied throughout the study.
An air sparger was used to agitate the bath liquid, although no heating was used.
After successful reduction of copper in the dead rinse, and thus in the running rinses, an ion
exchage unit was installed to remove copper from the drag-out tank. The deionized water was
returned to the last rinse bath. The ion exchange system consisted of a pump which supplied four
gallons of water per minute to the system. Two ion exchange tanks containing 1.4 cubic feet of
a strong acid resin were used. The dual system allowed one tank to be in service while the second
tank automatically regenerated or was in standby position. The technology resulted in reduction of
the copper concentration from 15 to 6 g/1 in the static rinse tank. In seven months of operation,
360 pounds of salvageable copper have been recovered by the electrowinner. As a consequence,
the concentration in the first counterflow rinse dropped from over 200 to below 50 mg/1.
The water coming from .the ion exchanger has copper levels well below 0.01 mg/1 and is
reintroduced into the second counterflow tank. It was necessary to change from city water to
softened water at the inlet. Regeneration is necessary every second day and takes about 20 minutes.
The run-off water from the first counterflow rinse contains 6 mg/1 of copper. It is transformed into
sludge in the waste treatment system.
5.2 Scale of Operation: Information not provided.
5.3 Stage of Development: Implemented, but tests are continuing.
5.4 Level of Commercialization: Information not provided.
2-32
-------
S.S Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Sludge, 60% dry,
Ibs/day
Water Use (gpm):
Energy Use:
Quantity
Before
18.5
4
N/A
Quantity
After
2.5
current density
8 ASF, surface area
of 20 sq.ft., 6V,
950 W
Assumptions: No absolute figures on sludge production are given. It is assumed all wastes of the
company are sent to the same facility.
As copper concentrations in the runoff water decreased by over 75 % (from over 200 to below 50
mg/1) and the runoff was reduced from 4 to 2 gpm, it is assumed that the amount of copper entering
the waste treatment facility from the experimental line decreased 87.5%. In the source document,
a 75 % reduction was claimed. The sludge production decreased by 16 Ibs/day. From these
figures, the before and after sludge production were computed.
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational & Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Use of this technology was prompted by tightening control on discharge limits and waste production in the
U.S.
Sludge production and water usage are reduced and salvageable copper are recovered.
8.0 Obstacles, Problems and/or Known Constraints '
Copper at low concentrations in the electrowinner burned while plating. Lowering current densities also
lowers plating to a rate at which the cell cannot keep pace with the drag-out rate. The running rinses had
to be fed with demi water.
9.0 Date Case Study Was Performed: November 1990 (date of source document)
10.0 Contacts and Citation
10.1 Type of Source Material: Magazine article
10.2 Citation: Reduce Water Consumption and Hazardous Waste. Jerome Kovach, Kinetico
Engineering Systems, Inc., Newbury, Ohio.
2-33
-------
10.3 Level of Detail of the Source Material: Additional information is available on the processes in the
source document.
10.4 Industry/Program Contact and Address:
Jerome Kovach, Kinetico Engineering Systems, Inc., Newbury, Ohio.
10.5 Abstractor Name and Address: M. Stein, RIVM, Dept. LAE, Anthonie van Leeuwenhoeklaan 1,
postbus 1, Bilthoven Netherlands. Reformatted: Barbara M. Scharman, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Copper plating bath
11.2 Process type/waste source: Electroplating, copper plating
11.3 Waste reduction technique: Electrowinning, ion exchange, drag-out reduction, copper recovery
11.4 Other keywords: Wastewater reduction
(*) - Disclaimer Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Copper Plating Bath, Electroplating, Copper Plating, Electrowinning, Ion Exchange, Drag-Out
Reduction, Copper Recovery, Wastewater Reduction, SIC 3471
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***** DOCNO: 450-003-A-350*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
Electrolytic recovery unit reduces loss of nickel through dragout in the first
standing rinse, allowing rinsewater to meet regulatory limits and reuse of
nickel.
Fabricated Metal Products/SIC 34
Sun Polishing & Plating, Ltd.
Toronto, Ontario
A nickel plating line for lighting fixtures addressed loss of nickel through
dragout in the first standing rinse with an electrolytic recovery unit. The
electrolytic chamber contains expanded steel mesh electrodes in a bed of
inert glass beads. The rinsewaters are pumped through the bed in
successive rinses until a nickel concentration of 3 ppm is achieved. The
scouring action of the beads on the surface of the electrodes ensures that the
ion concentration is maintained. The electrodes are periodically removed
when the deposits reach sufficient thickness, and the nickel is returned to
the plating tanks.
Rinsewaters from nickel plating
Rinsewaters, nickel
Water, solid
Not reported.
Requires less than 1/2 hour/day to maintain.
60
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
18 kg/week nickel recovered at about $7/kg, waste treatment costs
eliminated.
18 kg/week nickel.
Eliminates discharge of nickel containing rinsewaters.
The electrolytic recovery unit reduces the concentration of nickel in
rinsewater from 300 ppm to 3 ppm, which meets the regulatory limit of 5
ppm for nickel. Thus, waste treatment costs are greatly reduced, and 18
kg/week of nickel can be reused.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects",
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 42.
Recovery, Rinsewater, Electroplating, Electrolytic Recovery, SIC 34
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Use of a fluid bed reactor in an electroplating plant recovers nickel and reduces sludge
generation
2.0 SIC Code: 3471, Electroplating, Plating, Polishing, Anodizing, and Coloring
3.0 Name & Location of Company:
Chroomwerk
Kerkrade
4.0 Clean Technology Category: This technology uses a fluid bed reactor to recover nickel from plating
wastewater. The reactor is half filled with a special sand. Wastewater from the plating lines is mixed with
soda (NajCOj) and enters- from .below. The nickel crystallizes as carbonate on the sand grains which then
sink to the bottom of the column and are removed. The sand, 10 % of the weight of the material removed,
is reused in the reactor. The sedimented nickel is very pure and can be reused after acidification. The
effluent from the reactor is led over a filter, and partially reused.
5.0 Case Study Summary
5.1 Process and Waste Information: Wastewater from plating processes was originally treated in a DND
device. Over 80% of the nickel from the static rinses in three plating lines was recovered. Use of
the reactor and a filter removed over 99 % of the nickel from the wastestream. Using the new
technology results in a considerable reduction in both the amount of sludge produced from the DND
device and the effluent produced.
5.2 Scale of Operation: Not provided.
5.3 Stage of Development: A test installation proved to work satisfactorily so a full scale installation was
ordered in 1989. The new device will also be connected to four zinc plating automations for zinc
recovery.
5.4 Level of Commercialization: The equipment was purchased from DHV at Amersfoort, the
Netherlands.
5.5 Material/Energy Balances and Substitutions: No quantitive figures were given but the purchase of
metal salts, the amount of sludge produced, and the final effluent is reduced.
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational & Maintenance: Not reported
6.3 Payback Time: Not provided and could not be calculated.
7.0 Cleaner Production Benefits: The installment of the fluid bed reactor was inspired by both economical and
envionmental considerations, due to growth of the company and the concommitant increase in sludge
production. The amounts of sludge and effluent produced are less. Savings result from reduced purchasing
of metal salts.
8.0 Obstacles, Problems and/or Known Constraints: There were many start-up problems with the test
equipment but these were not specified in the source document.
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9.0 Date Case Study Was Performed: 1989
10.0 Contacts and Citation
10.1 Type of Source Material: Article
10.2 Citation: The fluid bed reactor in practice, advantages and disadvantages. W.L.J. Janssen.
Tijdschriift voor oppervlaktetechnieken en corrosiebestrijding. Vol. 33, No. 12, December, 1989.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was available
in the source document.
10.4 Industry/Program Contact and Address:
H.W. du Mortier
VOM
Jan van Eycklaan 2
Postbus 120
3720 AC Bilthoven
Netherlands
Phone 030-287111
Fax 030-287674
10.5 Abstractor Name and Address: Barbara M. Scharman, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Wastewater
11.2 Process type/waste source: Nickel plating
11.3 Waste reduction technique: Recovery, reuse
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Electroplating, Fluid Bed Reactor, Nickel Plating, Wastewater, Recovery, Reuse, SIC 3471
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Membrane electrolysis results in almost complete recovery of nickel from electroplating
wastewaters
2.0 SIC Code: 3471, Electroplating, Plating, Polishing, Anodizing, and Coloring
3.0 Name & Location of Company
Egidius Jansen
Witveldwegl4
5951 AV Belfeld
The Netherlands
Phone 04705-1444
4.0 Clean Technology Category
Technology Principle: This technology involves in-process modifications using membrane electrolysis to
recover nickel and reduce rinse water flow from electroplating processes.
5.0 Case Study Summary
5.1 Process and Waste Information: Water purification was previously accomplished in a DND
installation. For the new process, membrane electrolysis was selected because the high iron
concentration in the solution can impair electrolysis operation. The wastewater is sent to ion
exchangers where the stream of 4 nrVhr with 0.5 g/1 of nickel is concentrated to 10 m3/week with
a concentration of about 12 g/1. The wastestream is then passed to a membrane electrolysis cell
where 99.8% or 5000 kg/year of nickel is reclaimed through batch treatment. The nickel content
in the stream is reduced to less than 6 mg/1. The membrane in the cell is composed of perfluorinated
PTFE. The cell operates at 7 V and with 900 A 4 days/week. The new technology reduces the rinse
water flow, eliminates chlorine and sludge production, and recovers nickel for sale or reuse. There
is no effect on the final product
5.2 Scale of Operation: No information was provided.
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: From the case study, it was not clear whether the equipment was
purchased or developed in the plant itself. On further inquiry, it became apparent that the equipment
comes from Esmil, Diemen in the Netherlands.
5.5 Material/Energy Balances and Substitutions
5000 kg/year of nickel are reclaimed from the rinsewater.
6.0 Economics
6.1 Investment Costs: Investment costs for the electrolysis system were reported as Dfl 715,000. Capital
costs were reported as Dfl 100,000. No further breakdown was provided.
6.2 Operational & Maintenance Costs: Operating and maintenance costs were reported to be Dfl 5,000
for energy, Dfl 15,000 for labor, and Dfl 14,000 for maintenance.
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6.3 Payback Time: Nickel savings can be estimated to be about Dfl 100,000 since 5000 kg/year of
nickel are recovered at a rate of Dfl 20/kg. Savings on sludge hauling were not specified, however,
the amount of sludge not produced was indicated as "tens of tons" and hauling rates are estimated
at Dfl 300 to 500.
7.0 Cleaner Production Benefits
This process recovers nickel for sale or reuse, reduces the quantity of wastewater requiring further
treatment, and eliminates chlorine and sludge production. Benefits from improved public relations, reduced
liabilities, and changes in regulatory compliance were not discussed.
8.0 Obstacles, Problems and/or Known Constraints
One problem which arose during implementation of the technology was the plugging of anode compartments
with iron sludge from steel anodes. This was solved by using activated titanium anodes with a layer or
indium oxide which also increased efficiency. At the end of the process, a basic mist was produced above •
the anode compartments. This problem was eliminated by placing mist filters above the anode
compartments.
It was found that removal of nickel from the electrodes took about 5 to 6 hours. Using cathode cylinders
treated with a contact oil before starting the process decreased the time to about 2 hours. The problem of
the control of the voltage rectifier being destroyed frequently was corrected by using oil cooling instead of
air cooling.
9.0 Date Case Study Was Performed: January 1990 (date of source document)
10.0 . Contacts and Citations
10.1 Type of Source Material: Article
10.2 Citation: Membrane electrolysis in practice. J. Manders. Tijdschrift voor oppervlaktetechnieken
en corrosiebestrijding. Vol. 34, No. 1, January 1990, p. 14-16.
10.3 Level of Detail of the Source Material: Schematic diagrams of plating and membrane electrolysis
processes, including additional efficiency and mass balance data, are available in source document.
10.4 Industry/Program Contact and Address
Jan Ros
RIVM, dept LAE
Anthonie van Leeuwenhoeklaan 1
Bilthoven
Netherlands
10.5 Abstractor Name and Address: M. Stein, RIVM, anthonie van Leeuwenhoeklaan 1, Bilthoven,
Netherlands.
Reformatted: Barbara M. Scharman, Science Applications International Corporation, 7600-A
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Electroplating rinsewater, metal-bearing wastes
11.2 Process type/waste source: Electroplating, nickel plating, SIC 3471
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11.3 Waste reduction technique: Electrolysis, ion exchange, nickel recovery, reclamation, drag-out tanks
11.4 Other keywords: Sludge reduction, chlorine reduction, Netherlands
Keywords: Electroplating Rinsewater, Metal-Bearing Waste, Electroplating, Nickel Plating, SIC 3471, Electrolysis,
Ion Exchange, Nickel Recovery, Reclamation, Drag-Out Tanks, Sludge Reduction, Chlorine Reduction, Netherlands
2-40
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*****DOCNO: 400-073-A-310*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Ion exchange of chromium plating rinse tanks recovers chromium and
reduces wastewater generation rate.
Manufacture of Metal Products, Machines and Equipment/ISIC 38
This audit presents a modification of the rinsing stages of the conventional
chromium plating technology. After chromium plating, the parts are rinsed.
The first rinsing bath which is high in chromic acid, is recycled and the last
cold rinsing bath is regenerated on ion-exchange resins and recycled. In the
conventional process, the last cold rinsing bath is discarded.
For 1,000 m2 of treated surface:
18 kg chromic acid;
24 kg caustic soda and 60 kg sulfuric acid for resin regeneration;
2 kg barium carbonate for sulphate precipitation;
15 m3 water.
The only polluting residuals generated by the low-waste technology are
eluates from the regeneration process and the barium sulfate sludge. In the
standard technology, the most polluting residual stream is the last cold
rinsing bath.
Aqueous, solid
FF 2,200,000 (1978 figures), additional
FF 92 per 1,000 m2 of chromium plating surface (1979 figures), additional.
Not reported
No savings due to additional labor expenses
Not applicable
Elutes and sludge from regeneration
The low-waste technology can be applied to a large number of other surface
treatment related operations.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Chromium Metal Plating Followed by
Rinsing and by Regeneration of Rinse Water on Ion Exchange Resins with
Recycling", Monograph ENV/WP.2/5/Add.73.
Metal Finishing, ISIC 38, Ion Exchange, Resin Adsorption, Chrome
Wastes, Electroplating, Rinsewater, Recycle, Regeneration
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*****DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Replacement of hexavalent chromium with trivalent chromium in decorative chrome plating
reduces sludge generation
2.0 SIC Code: ISIC 3471, Electroplating, Plating, Polishing, Anodizing, and Coloring
3.0 Name & Location of Company:
W. Canning Materials Ltd.
P.O. Box 288
Great Hampton Street
Birmingham B18 6AS
UK
Phone 021-236-8621
Fax 021-236-0444
4.0 Clean Technology Category: The cleaner production is achieved by plating with trivalent rather than
hexavalent chromium. The tendency of trivalent chromium to be oxidized to hexavalent chromium was
overcome by using a special membrane surrounding the anodes. This also allows use of anodes made of
lead. The low deposition rates associated with trivalent chrome plating were grossly increased by using
specially developed in-house organic additives to modify the reactions and give performances superior to
the traditional process. This results in production which is 20-40% higher.
5.0 Case Study Summary
5.1 Process and Waste Information: Although the composition of the plating line was not clear from the
source document, it is assumed that the sequence consists of bright nickel plating with drag-out
recovery, two clean running rinses, chrome plate, two additional rinses, and a final hot rinse. In the
traditional process, hexavalent concentrations are sometimes as high as 120 g/I. Trivalent chromium
replaces hexavalent chromium in the new process and organic compounds are added. This results
in a decrease in sludge generation of over 95%, energy consumption reduced by over 50%, lower
current densities, no chloride in the electrolyte, and a 98% reduction in waste treatment costs. No
reduction chemicals are needed with the new process. Product quality was greatly improved due to
better coverage and more uniform plating.
5.2 Scale of Operation: Not provided.
5.3 Stage of Development: The technology has been fully implemented and in operation since about
1985.
5.4 Level of Commercialization: It appears the company has developed the procedure and sells it under
the name "Envirochrome-90". The membranes were developed for mercury-free electrolysis of
sodium chloride. Canning is a supplier of machineries to the electroplating industry.
2-42
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6.0
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste generation:
Energy use: Consumption
Current densities
*Exact quantities were not supplied.
Economics*:
Quantity
Before*
100%
100%
10-15Amp/dm2
8-12V
Quantity
After*
95%
50%
3.2-8Amp/dm2
7.0
8.0
6.1
Investment Costs: Actual figures on investments are not given, and these estimates may be low. A
comparison is made on the investment costs for a traditional plating line and the new plating process
for a plant producing 3 million nickel and chrome plated water fittings per year.
Plating plant
Effluent plant
Traditional
Technology
175,000
70,000
New
Technology
52,000
135,000
6.2 Operational & Maintenance: Only costs for water treatment were given for the traditional and new
technologies as follows:
Chrome reduction
Hydroxide precip.
Sludge disposal
Labor and materials
Total
Traditional
Technology
6,459
1,605
2,905
2,050
13,064
New
Technology
0
120
130
50
300
6.3
No costs were given for labor, maintenance of membranes, or energy consumption for other
operations. Membrane life is assumed to be indefinite since no signs of wear occurred after five
years of operation.
Payback Time: It is not possible to calculate a payback time due to lack of data but appears the
technology is relatively cheap compared to the traditional technology.
Cleaner Production Benefits: Sludge production decreased by 95%, waste treatment costs decreased by
98%, and power consumption decreased by over 50%. Electrical current densities are lower and the
electrolyte is less corrosive since no chloride is present. The technology appears to be cheaper than the
traditional process and results in improved product quality. Benefits from improved public relations,
reduced liabilities, and changes in regulatory compliance were not discussed.
Obstacles, Problems and/or Known Constraints: No problems were encountered although the brownish
color of trivalent chrome may be a problem for some people.
9.0 Date Case Study Was Performed: 1985
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10.0 Contacts and Citation:
10.1 Type of Source Material:
Document 1: UNEP report
Document 2: British government leaflet
Document 3: Plant leaflet
10.2 Citation:
Document 1: Title not given. B. Johnson, W. Canning Materials Ltd., P.O.Box 288, Great
Hampton Street, Birmingham B18 6AS, UK. Phone 021-236-8621, Fax
021-236-0444.
Document 2: Clean Technology. EPT Office, Department of the Environment, Room B 357,
Romney House, 43 Marsham Street, London SW1P SPY, UK. Phone 01-276-8318.
Document 3: Envirochrome Process Operating Guide. W. Canning Materials Ltd., P.O. Box 288,
Great Hampton Street, Birmingham B18 6AS, UK. Phone 021-236-8621, Fax
021-236-0444.
10.3 Level of Detail of the Source Material: Additional detail is available in the source documents on
some aspects of the manufacturing process.
10.4 Industry/Program Contact and Address:
Mr. Brian Johnson
W. Canning Materials Ltd.
P.O. Box 288
Great Hampton Street
Birmingham B18 6AS
UK
Phone 021-236-8621
Fax 021-236-0444
10.5 Abstractor Name and Address:
Barbara M. Scharman, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, VA 22043.
11.0 Keywords:
11.1 Waste type: Electroplating waste, metal-bearing waste
11.2 Process type/waste source: Chrome plating, membrane plating, SIC 3471
11.3 Waste reduction technique: Process modification, material substitution
11.4 Other keywords: Sludge reduction, chloride reduction, drag-out reduction, energy reduction, United
Kingdom
(*) - Disclaimer Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Electroplating Waste, Metal-Bearing Waste, Chrome Plating, Membrane Plating, SIC 3471, Process
Modification, Material Substitution, Sludge Reduction, Chloride Reduction, Drag-Out Reduction, Energy Reduction,
United Kingdom
2-44
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DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Removal of iron from a hardchrome plating bath by membrane extraction reduces energy needs,
plating bath replacement, and waste disposal costs.
2.0 SIC Code: SIC 3471, Electroplating, Plating, Polishing, Anodizing, and Coloring
3.0 Name & Location of Company:
Twentsche Hardchroom
Slijpsteen 10
Enschede
Netherlands
4.0 Clean Technology Category
5.0 Case Study Summary
5.1 Process and Waste Information: In the original process, the plating baths were substituted about once
every four years by a completely fresh bath solution. The old bath liquor originally was disposed
of, later on it was stored.
A continuous flow of hard chrome plating bath liquor is separated from a continuous flow of oxalic
acid by membranes selectively impermeable to iron ions (and possibly also other metallic ions). The
metal ions are induced to cross the membranes by an electrical driving force. The equipment operates
at 7 volts and 120 Amp. To prevent long pipelines running through the plant, a semi-batch approach
was chosen. The company decided to handle a volume of 1,000 (1m3) of bath liquor at the time.
This volume is pumped into a container and moves close to the actual iron extraction device.
Analysis of the bath liquor in the 1000 liter container over a ten day period confirms that 200
grams/day of iron are removed. Savings are achieved due to lower energy requirements, purchases
of bath solution, and hauling and disposal of baths. There were no effects on products.
5.2 Scale of Operation: The company employs 15 people in two shifts of eight hours/day, five
days/week. Several baths are in operation, the largest one has a content of 6,000 liters.
5.3 Stage of Development: The equipment, although commercially available, was still in the testing
stage. The producer is not yet very experienced with this type of device.
5.4 Level of Commercialization: The equipment is commercially available.
5.5 Material/Energy Balances and Substitutions:
No wastes are produced.
6.0 Economics*:
6.1 Investment Costs: Precise figures were not available but approximate costs were 100,000 guilders
(Dfl)(1990).
6.2 Operational & Maintenance Costs: These costs are estimated to be 1,000 Dfl/year. One man-hour
is required per week to clean the membranes.
6.3 Payback Time: Savings are estimated at 55,000 Dfl/year since the bath liquor does not neet to be
replaced at a rate of 4,000 liters/year. The payback time was estimated at between 2 and 3 years.
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7.0 Cleaner Production Benefits
Use of this technology was inspired by the following motives:
When a 600 liter bath, due to high iron content, had to be substituted, the electricity bill of the
company dropped Dfl 4,000 per month
The high costs of new bath liquor and haulage of the waste bath liquor
A stock of 20,000 liters (20 m3) of bath liquor with an iron content of 10 g/1
The reluctancy of the plant manager to let the disposed liquor be transported
The dissatisfaction of DND water purification, where waste is transformed from one form to another
but no waste prevention results.
Use of the technology resulted in decreased energy consumption, savings on bath solution purchases, and
savings on bath hauling and disposal.
8.0
Economic benefits were estimated as follows:
Decreased energy consumption
Purchase of bath solution
Bath haulage and disposal
Total
Obstacles. Problems and/or Known Constraints
24,000 Dfl/year
25,000
6,000
55,000
No problems were encountered, although the equipment was in operation for only three weeks at the date
of the case study.
9.0 Date Case Study Was Performed: December 1990
10.0 Contacts and Citation
10.1 Type of Source Material: Plant visit
10.2 Citation: Plant visit
10.3 Level of Detail of the Source Material:
10.4 Industry/Program Contact and Address:
H. W. du Mortier
VOM
Jan van Eycklaan 2
Postbus 120
3720 AC Bilthoven
Netherlands
Phone 030-287111 Fax 030-287674
10.5 Abstractor Name and Address: Submitted by UNEP Workgroup. M. Stein, RIVM, Dept. LAE,
Postbus 1, Anthonievan Leeuwenhoeklaan 1, Bilthoven, Netherlands.
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11.0 Keywords
11.1 Waste type: Electroplating baths
11.2 Process type/waste source: Electroplating, SIC 3471, hard chrome plating
11.3 Waste reduction technique: Membrane electrolysis, iron removal
11.4 Other keywords: Material conservation, energy conservation, Netherlands
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Electroplating Baths, Electroplating, SIC 3471, Hard Chrome Plating, Membrane Electrolysis, Iron
Removal, Material Conservation, Energy Conservation, Netherlands
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Electrolysis increases life of sulfuric acid bath and allows copper recovery.
2.0 SIC Code: ISIC 2085, Metal Plating
3.0 Name & Location of Company: Confidential
4.0 Clean Technology Category
Technology Principle: This process involves removing heavy metals from plating wastewaters by
electrolysis and ultrafiltration.
5.0 Case Study Summary
5.1 Process and Waste Information: The facility has one lead plating line where workplaces are treated
with sulfuric acid and copper is dissolved. A recirculating system is used for spray rinsing followed
by staining in a zinc chloride bath. Thermal lead plating in a bath containing 6% tin is then
followed by immersion in a cooling bath. A spray bath and a final immersion bath complete the
process. Changes to the process included the addition of the cooling bath after the actual plating
bath and the regeneration cell parallel to the acid bath. The wastewater has been separated from
the sanitary wastewater at the plant. The remaining wastewater is first sent to a collection pit and
a storage tank. It is then treated in a mixing tank with lye and after flocculation goes to an
ultrafiltration system. The permeate is sewered and the concentrate thickened in a filter press.
The new measures involved constructing a regeneration cell parallel to the sulfuric acid bath to
recover the dissolved copper. This has resulted in a considerable increase in the lifetime of this
bath. The immersion bath cools the workplaces and removes copper oxides.
Water consumption at the facility is greatly reduced with the process modification. Wastewater
flows of 18,000 nrVyear, containing 4,000 - 5,000 kg of heavy metals, has been reduced to
10,000 nrVyear, containing 700 kg of heavy metals. The new process requires small amounts of
chemicals for neutralization and flocculation. Sludge is a new waste product resulting from the new
process. No effects on product quality were experienced.
5.2 Scale of Operation: The facility employs one worker for 1800 hours/year and.has a production
capacity of 30 tons of lead per year, deposited in a layer less than 100/un thick.
5.3 Stage of Development: The measures are fully implemented.
5.4 Level of Commercialization: All equipment needed is widely available.
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5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation (kg/year):
Heavy metals
Sludge, 23 % dry matter
Copper
Zinc
Nickel, chrome, lead
Quantity
Before
4,000-5,000
0
N/A
N/A
N/A
Quantity
After
<2
10,000
<1
<1
immeasurable
6.0
7.0
8.0
9.0
Water Use (nrVyear): 20,000
(including 2,000 m3/year sanitary)
12,000
Economics*
6.1 Investment Costs: Investment costs (Dfl) for the new process are as follows:
Regeneraton cell at acid bath
Separation of wastewater streams
Wastewater treatment system
36,000
33,000
235,000
Capital costs reported separately in the source document were included here with investment costs.
6.2 Operational & Maintenance Costs: The following costs (Dfl) are required to operate the system:
1,500
2,000
2,000
800
4,000
10,000
2,000
1,000
Inline:
Cooling bath
Regeneration cell maintenance
Regeneration cell operation
Wastewater treatment system:
Chemicals (e.g. NaOH)
Sludge removal
Operation (6 manhours/week)
Energy
Analyses
6.3 Payback Time: Not reported
Cleaner Production Benefits
Installation of the equipment was promoted by water regulation demands. Water consumption, wastewater
quantities, and the quantity of heavy metal contained in wastewaters are decreased.
Obstacles, Problems and/or Known Constraints
Some minor start-up difficulties were experienced but not specified.
Date Case Study Was Performed: August 1986
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10.0 Contacts and Citation
10.1 Type of Source Material: Report on company interviews
10.2 Citation
Wastewater Problems in the Metal Industry. Results of interviews in 48 companies. Dr. W.H.
Rulkens, TNO, Maatschappelijke Technologic, postbus 342, 7300 AH Apeldoora, Netherlands, tel
(055) 773-344.
10.3 Level of Detail of the Source Material: Not reported
10.4 Industry/Program Contact and Address:
H.W. du Mortier
VOM
Postbus 120
3720 AC Bilthoven
Netherlands
Phone 030-287111
10.5 Abstractor Name and Address: M. Stein, RIVM, Dept. LAE, Anthonie van Leeuwenhoeklaan 1,
Postbus 1, Bilthoven, Netherlands. Reformatted: Barbara M. Scharman, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Plating wastes, metal-bearing wastes
11.2 Process type/waste source: Lead plating, ISIC 2085
11.3 Waste reduction technique: Electrolysis, ultrafiltration, regeneration cell, cooling bath, reclamation,
copper recovery
11.4 Other keywords: Wastewater reduction, Netherlands
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Plating Wastes, Metal-Bearing Waste, Lead Plating, ISIC 2085, Electrolysis, Ultrafiltration,
Regeneration Cell, Cooling Bath, Reclamation, Copper Recovery, Wastewater Reduction, Netherlands
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***** DOCNO: 400-124-A-331*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST-
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Rotalyt-Alutop process for aluminum plating reduces discharge of cadmium
into the environment while also reducing costs.
Corrosion Protection of Small Components/ISIC 3844
The Rotalyt-Alutop process for aluminum plating is based on the
chemo-mechanical plating of pieces in a medium containing an impact body,
and metal particles and catalysts, using relative movement. The pieces are
loaded into a perforated drum, and lowered into a plating bath where glass
balls are added as the impact body and the aluminum flakes are added. The
drum passes through a separation tank where the glass balls are separated
for reuse, to a centrifuge unit, and to an unloading station for drying. The
cathodic corrosion protection properties are considerably improved by the
use of zinc containing aluminum alloys, or preplating to add a zinc/tin
layer.
Electric energy-140 kWh/ton, Al metal-14 kg/ton, rinse water-200 I/ton,
catalyst-5 kg/ton, pre- and post-treatment-20 kg/ton
Wastewaters, chemical baths
Aqueous
500,000 DM (1983)
294 DM/ton treated goods
Not reported
100,000 DM reduction in capital cost,. 94 DM/ton of treated goods
reduction on process costs.
Electrical requirements reduced by 780 kWh/ton, rinsewater by 800 I/ton,
14 kg/ton Al required compared to IS kg/ton Cadmium, treatment
chemicals by 100 kg/ton.
Wastewaters produced from conventional process contains cadmium,
cyanide, and chromium compounds. The waters are neutralized,
precipitated, and dumped. The low waste technology reduces the toxicity
of the waste.
Reduction of environmental pollution from the proven toxicity of cadmium
while reducing costs.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, Monograph "Rotalyt-Alutop"
ENV/WP.2/5/Add. 124.
Electroplating, Aluminum, Wastewater Treatment, Metal Treating,
Corrosion, Rotalyt-Alutop, ISIC 3844
2-51
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***** DOCNO: 400-125-A-332*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Aluminum used instead of cadmium in conventional electroplating
technology eliminates cadmium and cyanide-containing waters and
hydroxide sludge, while reducing operating costs.
Manufacture of Structural Metal Products/ISIC 3813
Conventional electroplating technology using aluminum instead of cadmium
as the plating metal. A thin layer of nickel is initially deposited on ferrous
and aluminum die casting materials. The pieces are dried using
fluorohydrocarbons, and passed to the aluminum plating cell. Using an
electrolyte solution, an aluminum layer is applied to the nickel coating. A
post-treatment process may be applied to improve corrosion protection or
for decorative appearance.
Nickel-18 g/m2, Al-27 g/m2, electrolytic bath (recycled), electrical energy
No wastewaters (electrolyte is recycled), evaporation of toluene from the
bath (1-2 kg/hr)
Vapor
6 million Dfl - 40 nrVhr plant
50 - 75 Dfl/m2
Not reported
10 - 15 Dfl/m2 reduction in operating costs, elimination of wastewater
treatment and disposal costs.
18 g of Ni, and 27 g Al is require compared to 180 g Cd, and 5 g CN in
conventional technology.
Cd and CN containing wastewaters are eliminated. 1-2 kg/hr toluene vapor
is produced.
Elimination of Cd and CN containing waters and hydroxide sludge, with
reduced operating costs. Discharge of the bath contents occurs after two
years, and the materials are recycled.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, Monograph "A Low-waste Electroplating
Process of Aluminum in Non-aqueous Solvent (Sigal-Process)"
ENV/WP.2/5/Add. 125.
Electroplating, Aluminum, Wastewater Treatment, Metal Treating,
Recycling, ISIC 3813
2-52
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***** DOCNO: 400-126-A-333*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COSTS:
OPERATING/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Blue passivation process in the galvanic industry uses trivalent chromium
(instead of hexavalent chromium) to allow for reuse of chemical bath, less
aggressive rinsewaters and lower operating costs.
Manufacture of Structural Metal Products/ISIC 3813
The use of trivalent chromium for the Blue Passivation process in the
Galvanic Industry instead of hexavalent chromium leads to a no-dump bath.
The conventional technology for the chromating of zinc coatings utilizes
hexavalent chromium and mineral acid, which reacts with the metal. In
addition to the chemicals present in the bath, the wastewater also contains
zinc that was dissolved from the metal surface. The low-waste technology
utilizes Cr(III) and H2O2 which dissolves little zinc and the bath can be
replenished with concentrate and reused.
Cr(III), H2O2 (30%), citric acid
Wastewater containing Cr(III) - 200 g, H2O2 - 8 ml, citric acid - 600 g, zinc
- 750 g (treated by reduction and precipitation of hydroxide) per 1000 m2
chroma ted.
Aqueous
Only material and discharge costs involved.
40 Dutch guilders/1,000 m2 of passivated metal surface.
Not reported
Operating costs are reduced by 190 Dutch guilders/1,000 m2 of passivated
metal.
0.75 kg zinc dissolved in bath compared to 7.5 kg of lost zinc using
conventional technique, allowing for reuse of the bath.
Chemical baths are reused, rinsewaters contain less aggressive H2O2 and
citric acid, compared to conventional method, resulting in savings of 171.50
Dutch guilders in discharge costs.
The use of trivalent chromium over hexavalent chromium in passivating
zinc metals allows for reuse of the chemical bath, less aggressive
rinsewaters and lower operating costs.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, Monograph " A No-dump Bath Using
Trivalent Chromium for the Blue Passivation Process in the Galvanic
Industry" ENV/WP.2/5/Add. 126.
Metal Finishing, Recycling, Chrome, Chromating, ISIC 3813
2-53
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*****DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
4.0
Headline: Removal of cations from chromic acid and evaporation result in decreased sludge production
and energy consumption
SIC Code: SIC 3471, Electroplating
Name & Location of Company: Koni BV
Langeweg 1
Oud-Beyerland
Netherlands
Phone (01860)12500
H. van Zessen
Clean Technology Category: This technique involves use of a cation exchanger for continuous cleaning
of drag-out baths and evaporation followed by water reuse.
5.0 Case Study Summary
5.1 Process and Waste Information: The plant operates a three step cascade rinse behind the plating
baths and the water is used to replenish the water evaporating from the process baths. This is
supplemented with demi water. In the original process, a final rinse with tap water occurred after
the cascade.
Because of a build-up of undesired cations such as iron, copper, and nickel in the process baths,
drag-out baths are now treated over a cation resin. The water of the final rinse has been substituted
with demi water and is also treated over the resin. The process liquor is too aggressive to be
treated. By using the waste heat of the cooling system and controlling the process bath temperature,
an extra amount of water is evaporated. The resulting wastewater is still treated in a DND
installation. Lifetime of the untreated baths was about five years with the original process.
In the original process, the starting power was 10 V and 15,000 Amp. The voltage increased at
a rate of 1 V/A. Due to limitations in the transformers, this meant that after about five years the
process baths had to be thrown away. In the current situation, the voltage increased two volts in
five years of operation, and then remained stable.
Sludge production decreased from 10 tons to 0.4 tons in five years and 60 regenerations of the
cation exchanger were performed using 1500 liters of hydrochloric acid. Tap water consumption
decreased from 1330 to 15 m3/year and demi water consumption went up 1320 mVyear. Energy
consumption decreased from 99 MWh/year to 59 MWh/year or more than 40%. The consumption
of chromic acid decreased by 2,000 liters/year and chemicals for the DND installation decreased
from 2,000 to 20 liters/year.
No effects on product quality were reported in the source document although quality should have
improved since foreign elements have been removed.
5.2 Scale of Operation: Not reported
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: All necessary parts are widely available.
2-54
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5.5 Material/Energy Balances and Substitutions:
Material Category Quantity
Before
Quantity
After
6.0
7.0
Waste Generation:
Sludge (tons)
Feedstock Use:
New chromic acid (tons)
HC1 (liters in 5 yrs.)
Chemicals for DND (tons)
Water Use:
Tap water (nrVyear)
Demi water (mVyear)
Energy Use:
(MWh/year)
10
10
0
10
1330
N/A
99
0.4
N/A
1500
0.1
15
increased by
1320 nrVyear
59
Economics*:
6.1 Investment Costs: Not reported
6.2 Operational & Maintenance Costs: Costs for the five year period are as follows:
New chromic acid
Waste disposal
Chemicals for DND
Power loss
Tap water
Extra demi water
Sewage costs
Old Process
(T>fn
15,000
3,500
40,000
74,250
8,600
9,550
New Technology
140
400
44,550
100
33,000
100
6.3
Payback Time: Costs over five years have decreased by Dfl 71,710. Since no investment costs
were given, a payback period cannot be calculated. However, based on the cost information given
and the cost of an ion exchanger, it can be estimated that the payback period would be less than one
year.
Cleaner Production Benefits: The new technology resulted in decreases in power consumption, undesired
metals in the deposited layer, sludge production, chromic acid, and chemicals needed for wastewater
treatment. The following are savings realized using the new process:
Less chromic acid
DND treatment chemicals
Waste disposal
Power consumption 5340
Tap water
3,000 Dfl/year
8000
700
1900
8.0 Obstacles, Problems and/or Known Constraints: No obstacles or problems were discussed.
2-55
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9.0 Date Case Study Was Performed: Probably early 1990
10.0 Contacts and Citation
10.1 Type of Source Material: Example report
10.2 Citation: Removal of cations from chromic acid by continuous cleaning of drag-out baths through
a cation resin and evaporation before reuse. Jan Ros, RlVm, Dept. LAE, anthonie van
Leeuwenhoeklaan 1, Postbus 1, 3720 BA Bilthoven, Netherlands.
10.3 Level of Detail of the Source Material: More detailed information is available on the process.
10.4 Industry/Program Contact and Address:
H.W. du Mortier
VOM
Jan van Eycklaan 2
Postbus 120
3720 AC Bilthoven
Netherlands
Phone 030-287111
Fax 030-287674
10.5 Abstractor Name and Address: M. Stein, RIVM, Dept. LAE, Anthonie van Leeuwenhoeklaan 1,
Postfaus 1, 3720 BA Bilthoven, Netherlands. Reformatted: Barbara M. Scharman, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords:
11.1 Waste type: Plating baths
11.2 Process type/waste source: Electroplating, SIC 3471
11.3 Waste reduction technique: Ion exchange, evaporation
11.4 Other keywords: Sludge reduction, energy reduction, Netherlands
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Plating Baths, Electroplating, SIC 3471, Ion Exchange, Evaporation, Sludge Reduction, Energy
Reduction, Netherlands
2-56
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1.0
2.0
3.0
4 0
DOCNO: DOCUMENT NOT AVAILABLE *****
Headline: Water and Waste Reduction in Electroplating Using Static Rinses and Ion Exchange Columns
SIC/ISIC Code:
Name and Location of Company:
FSM Sosnowiec, Poland
Clean Technology Category: The facility modified its plating system to replace overflow rinses with static
rinses. In addition, the final rinse tank in each plating line is equipped with ion exchange columns to
permit water recycling and raw materials recovery.
5.0 Case Study Summary:
5.1 Process and Waste Information: FSM Sosnowiec manufactures automobile parts using copper-
nickel-chromium plating and zinc plating. The wastestreams contain cyanide, hexavalent chromium,
copper, zinc, and nickel. After a pollution prevention audit, the facility reduced water usage by
93 percent through minor process/equipment modifications.
5.2 Scale of Operation: Not provided.
5.3 Stage of Development: The practices are currently being implemented at FSM Sosnowiec.
5.4 Level of Commercialization: The practices are operational modifications and are readily available.
5 5 Material/Energy Balances and Substitutions: The reduction in waste stream quantities include:
chromic acid-80 percent, copper-95 percent, cyanide-80 percent, nickel-98 percent, zinc-96 percent,
and wastewater 93 percent. Wastewater is treated to the following levels: chromium-0.1 mg/1,
copper-0.1 mg/1, nickel-1.0 mg/l, cyanide-2.0 mg/1, and zinc-0.9 mg/1.
6.0 Economics*
6.1 Investment Costs: The capital investment is US$36,000.
6.2 Operational and Maintenance Costs: The modifications save the facility approximately US$193,000
a year.
6.3 Payback Time: Two months.
7.0 Pollution Prevention Benefits
The process modifications decrease both the water and raw materials consumption and reduces the amount
of pollutants to be treated in the plant effluent.
8.0 Obstacles, Problems, and/or Known Constraints
None identified.
9.0 Date Case Study Was Performed: Not Provided.
10.0 • Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
2-57
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10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Waste Reduction in Electroplating," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mrs Mirostawa Domino, Mr Zdzistaw Twardon,
Environmental Protection Department, FSM Sosnowiec, Pekin Street 1,41-200 Sosnowiec, Poland,
Tel: +48 32 63 84 01 ext 210 -
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Electroplating
11.3 Waste Reduction Techniques: Static rinsing
11.4 Other Keywords: Ion exchange
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600A Leesburg Pike, Falls
Church, Virginia, 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Electroplating, Static rinsing, Ion exchange
2-58
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***** DOCNO: 450-003-A-381*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Use of ion-exchange metal recovery system meets space and waste reduction
requirements.
Transportation Equipment/ISIC 32
G. G. Buffing & Plating
Longuevil, Quebec
T. Nadeau
A chemical recovery system was built above a plating line of an
electroplating plant that plates decorative copper, nickel and chromium on
a variety of components and trim for automobiles and motorcycles.
Short-bed ion exchange systems, designed and built by Eco-Tec of Ontario,
were installed on the copper, nickel and chromium rinses. This system was
chosen over a conventional waste treatment system, because limited space
(20 x 15 feet) was available, and the payback was more attractive.
Copper, nickel, chromium rinsewaters
Rinsewaters, unrecovered metals
Water
$125,000 (comparable to that of a destruction/precipitation treatment
system)
The plating manager monitors and maintains the units for approximately
1-1/2 hrs/day.
Not reported
$13,257 for first year, projected to be $60,222 when line reaches full
capacity of 6,000 hrs/year.
Recovered metals reduce quantities of raw material to be purchased.
Recovered metals no longer require disposal.
In addition to meeting the company's space requirements, this ion-exchange
system recovers metal from plating baths, reducing the waste for disposal
as well as raw material needs.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects",
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 96.
Electroplating, Metal, Ion Exchange, Recovery, ISIC 32
2-59
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Clean technology measures result in minimal waste production in electroplating shop of a large
company
2.0 SIC Code: SIC 3471, Electroplating, Plating, Polishing, Anodizing and Coloring
3.0 Name & Location of Company: Confidential
4.0 Clean Technology Category
Technology Principle: Processes were designed to minimize heavy metal concentrations in rinsewaters and
continuous treatment of process bath liquid in order to result in minimal water usage and waste generation.
«5.0 Case Study Summary
5.1 Process and Waste Information: The plant operates twelve lines for all kinds of electrolytical
surface treatment. Not all lines contain static rinses and one line contains cascade rinsing. In order
to minimize waste generation, the lines are operated manually and drip plates are used between
baths. Long drip-off times are achieved with slow movements in the process and workplaces are
hung carefully. Static rinses are used where possible and a complete return of static rinse water
into the process baths is achieved. Continuous treatment of process bath liquid maintains a constant
bath quality. This includes electrolytic recovery of silver, activated carbon treatment, and filtration.
Intense monitoring of baths maintains a constant composition and the lowest concentration of
process chemicals possible is used.
The rinsewater streams of all lines are collected into one stream and sent to a water treatment
system. Wastewater and concentrates of outside dischargers are also treated in the system. The
contaminated water (200,000 m3/year) is treated in an ion exchanger then is returned to the plant.
A small part of the processed water is first sent to an extra mixed bed ion exchange device for more
purification, and then returned to the plant. The regenerate of the ion exchanger is treated in a
DND device, the neutralized water is filtered by a filter press and, if necessary, led over a selective
ion exchanger to remove cadmium. The pH is corrected and the water is sewered. The sludge is
removed as chemical waste and transported to Western Germany.
The rinsewater leaving the electroplating plant (200,000 m3/year) has an estimated concentration
of 5 - 30 mg/1 of heavy metals. The final water released to the local sewer system has heavy metal
concentrations far below the regulatory limits. Due to treatment of water and concentrates from
outside dischargers, 600 nrVyear - 1500 mVyear are released to the sewer system. The process was
installed, as described above, at the outset of operation. These measures are not changes to the
process.
5.2 Scale of Operation: Five people work in the electroplating shop. The plant capacity was not
provided. Three people are employed in the water treatment unit which has a capacity exceeding
200,000 mVyear.
5.3 Stage of Development: The plant has been operative since 1968 and has undergone only slight
modifications for process improvements since then.
5.4 Level of Commercialization: All necessary components are widely available.
5.5 Material/Energy Balances and Substitutions:
The measures were installed when the plant became operational so there is no "before" situation.
The electroplating shop produces 200,000 mVyear of contaminated liquids but this amount is
2-60
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completely reused after purification. The sludge production is 150 tons/year of about 30% dry
materials.
6.0
7.0
8.0
9.0
10.0
Economics*
6.1
Investment Costs: Investment costs include Dfl 1,700,000, of which Dfl 300,000 were from
construction of buildings. Capital costs were Dfl 1,000,000. The costs of the in-process measures
cannot be estimated since they were part of the original investment. These costs are from 1970.
According to the company these costs would have tripled by 1986.
6.2 Operational & Maintenance Costs: Annual costs for the water purification system are as follows:
Maintenance and operation
Energy
Chemicals, .100 tons/year
Sludge removal, 150 tons/year
200,000 Dfl
30,000
100,000
50,000
6.3 Payback Time: Payback time could not be calculated.
Cleaner Production Benefits
Reusing the water saves the company about Dfl 200,000/year. Recovery of metals saves about
150,000/year based on estimates of interviewers.
Obstacles, Problems and/or Known Constraints
None were reported.
Date Case Study Was Performed: August 1986 (date of source document)
Contacts and Citation
10.1 Type of Source Material: Report based on interviews with 48 companies.
10.2 Citation: Wastewater problems in the Metal Industry: Results of Interviews with 48 Companies.
Dr. Ir WH. Rulkens, TNO, Maatschappeliijke Technologic, Postbus 342, 7300 AH Apeldoom,
Netherlands, tel (055) 773 344.
10.3 Level of Detail of the Source Material:
10.4 Industry/Program Contact and Address
H. W. du Mortier
VOM
Jan van Eycklaan 2
Postbus 120
3720 AC Bilthoven
Netherlands
Phone 030-287111
Fax 030-287674
10.5 Abstractor Name and Address: M. Stein, RIVM, Dept. LAE, Anthonievan Leeuwenhoeklaan 1,
Postbus 1, Bilthoven, Netherlands. Reformatted: Barbara M. Scharman, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
2-61
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11.0 Keywords
11.1 Waste type: Electroplating rinsewater
11.2 Process type/waste source: Electroplating, SIC 3471
11.3 Waste reduction technique: In-process measures, cascade rinsing, electrolytic recovery, silver
recovery, carbon adsorption, ion exchange, wastewater treatment
11.4 Other keywords: Germany
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Electroplating Rinsewater, Electroplating, SIC 3471, In-Process Measures, Cascade Rinsing,
Electrolytic Recovery, Silver Recovery, Carbon Adsorption, Ion Exchange, Wastewater Treatment, Germany
2-62
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***** DOCNO: 400-101-A-262 *****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Chemelec electrolytic cell recovers pure metal from static rinses for recycle
to plating baths, reducing wastewater treatment sludge volume.
Manufacture of Fabricated Metal Products, Machinery and Equipment/ISIC
38
The "Chemelec" electrolytic cell recovers pure metal from a moderately
dilute static rinse. The metal is recycled directly to the plating bath as
dissolving anodes. The "Chemelec" cell is an electrolytic device which
economically deposits metal of high quality from solutions containing 100
to 1,000 mg/1 of heavy metal. Expanded metal mesh electrodes immersed
in a bed of 0.5 mm glass beads impinge on the electrodes, continually
renewing the depleted boundary layer adjacent to them, and providing an
enhanced rate of deposition. The cell is used to maintain an electroplating
drag-out tank at a low concentration, so that metal losses into the drain or
as hydroxide sludge are reduced by a factor of about 100. The recovered
material is recycled directly to the plating bath as dissolving anode material.
Not reported
Aqueous metal-laden plating waste.
Aqueous
British Pounds
5,200 for a cell with steel anodes and cathodes for alkaline cyanide solution
(i.e., zinc, cadmium); 8,100 for a cell with titanium cathodes and
noble-metal-oxide-coated titanium anodes for acidic solution (i.e. nickel,
copper)
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
The amount of hydroxide treatment sludge is reduced. This development
is of great relevance to the sewage sludge disposal problems encountered in
public effluent treatment.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "The "Chemelec" cell for Recycling of
Metal in the Electro-plating Industry", Monograph ENV/WP.2/5/Addl01.
ISIC 38, Chemelec, Electrolytic Recovery, Electroplating
2-63
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DOCNO: 400-127-A-334*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COSTS:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
OTATiON/PAGE:
KEYWORDS:
Use of providence method for rinsing electroplated parts reduces volume of
metals in rinsewater and allows recovery of the dragout and reuse of
rinsewaters.
Manufacturing of Fabricated Metal Products, Machinery, and
Equipment/ISIC 3800
The "Providence Method" (PM) is a low-waste process for rinsing of
electroplated parts. The method is designed to remove the majority of
contaminating metals from rinsewater in a small volume before utilizing the
conventional flowing rinse which flows at a fairly high rate to ensure good
product quality. The PM tank is frequently set up as a counter-current tank
in order to remove a sufficient quantity of dragout (metals). Some of the
solution from this counter-current PM is used as make-up solution to raise
the level in the plating tank following evaporation or excess dragout.
Rinsewaters, spent solutions from plating and cleaning operations
Contaminated wastewaters
Aqueous
$24,000 - $89,000 (dependent on capacity of plant)
$9740 - $133,570
Total capital and operating costs are lower than conventional technology.
For conventional processes of equal capacities, ranges are $63,750 -
$421,600 for capital costs and $26,960 - 180,430 for operating costs.
Some make-up solution is recycled from the PM process.
Total volume of waste requiring treatment is reduced as well as the
concentration of the waste.
The use of low-volume rinsing in surface finishing, and electroplating
processes reduces the volume of metal containing wastewaters, and allows
for recovery of the dragout. Additionally, investment and operating costs
are reduced primarily due to reduced treatment costs.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, Monograph "Use of Low-volume Rinsing in
surface Finishing, Electroplating Processes" ENVAVP.2/5/Add. 127.
Metal Finishing, Metal Recovery, Counter-Current Rinsing, Wastewater
Treatment, Dragout, Electroplating, Providence Method, ISIC 3800
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***** DOCNO: 450-012-A-001*****
1.0 Headline: Quebec electroplating company decreases effluent and saves money on chemical and treatment
costs
2.0 SIC Code: 3471
3.0 Name and Location of Company
Galvano
Saint-Mathieu-de-Beloeil, Quebec
4.0 Clean Technology Category: This technology involves wastewater reduction, process/equipment
modification, and waste segregation/separation.
5.0 Case Study Summary
5.1 Process and Waste Information
Because of elevated levels of zinc found in the groundwater surrounding Galvano's factory, the
owners decided to implement a new system in 1981 to treat the wastewaters from this electroplating
company. They decided to implement a system that would decrease the amount of effluent while
incorporating a treatment system that would precipitate metals out of the effluent. In order to
decrease the volume of the waters to be treated, the company separated refrigeration waters from
the contaminated effluent. This action alone decreased the amount of waters to be treated from 810
to 270 liters/min. A system of counter-current rinsing was put in place to further decrease the
volume of effluent. Also, deflectors were positioned between the acid and alkaline basins to
recover drippings from metals pieces so that the liquids could be returned to their respective
solutions. Using counter-current rinsing and the deflectors decreased water usage from 270
liters/min. to 100 liters/min. The decrease in water consumption resulted in savings of $20,000.
Total reduction in the effluent volume was 87%. By eliminating and reorganizing the rinsebaths,
the company was able to rearrange enough space to add more plating lines and increased production
by 100%.
The company realized, however, that a reduction in the volume of effluents didn't necessarily mean
that the contamination of these waters would be decreased. By centrifuging the basket where "hot
zincing" takes place and by increasing the time between cleanings by 50%, the company was able
to recover 1 ton of zinc/day and save $l,000/day. By using a special pump to adjust the levels of
water in the rinsebaths, the concentration of contaminants was able to be controlled. This action
conserved mineral salts necessary to the process and decreased the amount of zinc and potassium
chloride and boric acid used. Also, the company's normal sand filtering system was replaced by
another in which more filters were added to decrease the cumber of times the rinsebaths needed
cleaning and decreased the number of chemicals needed to maintain the baths. The pumping system
and the new filters enabled the company to save $28,000/year in chemical costs. This decrease in
chemicals decreased the amount of residual sludge which saved $20,000/year in treatment costs.
Total treatment cost savings were approximately $70,000/year due to a 10% reduction in sludge.
Total cost savings were approximately $368,000/year due to the decrease in the amount of effluent
and increase in the capture of metals. The company was also able to increase its production by
100%.
5.2 Scale of Operation: Galvano operates 24 hours/day and employs about 50 people. It is the most
productive electroplating plant in Quebec, plating approximately 2,500 tons/year of bolts, screws,
nails, and similar products.
2-65
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6.0
7.0
8.0
9.0
10.0
5.3 Stage of Development: This technology was fully implemented at the time of this case study.
5.4 Level of commercialization: This technology was commercially available at the time of this case
study.
5.5 Material/Energy Balances and Substitutions
Quality of Effluent
Chemicals
Cr
Zn
HandG
Fe
pH
Before
Treatment mg/1
.91
500
215
100
1.0-8.0
After
Treatment mg/1
.1
.69
4.6
1.0
7.5-8.5
Standards
me/I
1
1
15
17
5.5-9.5
Economics*
6.1 Investment Costs: Information not provided.
6.2 Operation and Maintenance Costs: Operation and maintenance costs were not provided.
6.3 Payback Time: With the system fully implemented, payback starts immediately.
Cleaner Production Benefits: Savings in chemical and treatment costs are as follows:
Technology
1) Decreasing consumption of water
2) Decreasing consumption of chemical products
3) Reduction of contaminated sludges
4) Recovering zinc and increasing the period
between cleanings of baskets
It is assumed that costs were reported in Canadian dollars.
Savings
$20,000
$28,000
$20,000
$300.000
Total $368,000
Production was increased by 100% after rinse baths were eliminated or reorganized. The company is now
in compliance with the effluent standards of Quebec.
Obstacles, Problems and/or Known Constraints: Information not provided
Date Case Study Was Performed: The case study was performed in 1981.
Contacts and Citations
10.1 Type of Source Material: Report
10.2 Citation: Secteur Revetement de Surface, Technologies Propres. Electrogalvanization et zingage
a chaud. Gouvemement de Quebec, Ministre de 1'Environnement, Gestion et Assainissement des
Eaux, revised June 1988. Source document is in French.
2-66
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10.3 Level of Detail of the Source Material: More detail is provided about the general process of
electroplating.
10.4 Industry/Program Contact and Address: Regional offices, addresses and phone numbers are given
on the back of the report.
10.5 Abstractor Name and Address: Blair M. Raber, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, VA, 22043.
11.0 Keywords
11.1 Waste Type: Electroplating rinsewater, Acidic Wastewaters, Alkaline Solution, Zinc.
11.2 Process Type/Waste Source: Electroplating, Plating and Polishing, Rinsate, Sludge, Zinc
Galvanization.
11.3 Waste Reduction Technique: Counter-Current Rinsing, Metal Recovery, New Equipment, Process
Modification, Pumps and Pumping Equipment, Volume Reduction, Wastewater Reduction, Source
Reduction, Drip Confinement, Sand Filter.
11.4 Other Keywords: Bolts, Nuts, Screws and Rivets; Increased Productivity, Metal Products.
(*) Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Electroplating Rinsewater; Acidic Wastewaters; Alkaline Solution; Zinc; Electroplating; Plating and
Polishing; Rinsate; Sludge; Zinc Galvanization; Counter-Current Rinsing; Metal Recovery; New Equipment; Process
Modification; Pumps and Pumping Equipment; Volume Reduction; Wastewater Reduction; Source Reduction; Drip
Confinement; Sand Filter; Bolts, Nuts, Screws and Rivets; Increased Productivity; Metal Products
2-67
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FERTILIZER
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***** DOCNO: 400-010-A-201 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Reduced energy consumption and wastewater generation achieved in nitric
acid production.
Fertilizer Industry, Nitric Acid Production/ISIC 3512
National Authority for Environmental Protection and Nature Conservation
- Veszprem University of Chemical Engineering -Nitrogen Works Pet,
Hungary
The company uses a pressurized process with catalytic end-gas reduction
(GIAP). This includes:
Oxidation ammonia - oxidation HO - absorption NOX - catalytic end-gas
reduction.
End gas 3.300 m3 with NOX content (vol. %) 0.1 - 0.15 (The conventional
process produces an end-gas with an NOX content (vol. %) of 0.2 - 0.4)
Acidic wastewater effluent of 1-3 m3/day with NO3 - content of 5g/l. (The
wastewater volume from the conventional process is about 5-15 nrVday.)
End-gas amounting to 4.100 NH3/ton of HNO3 with an NO - content (vol
%) of 0.005 per cent, CO-content of 0.1 per cent, and COj - content of 2.5
percent.
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Dramatically reduced energy consumption, but dramatically increased
catalyst consumption. Stack gases and waste heat increase but wastewaters
are decreased significantly.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Comparison Between Conventional and
Low-Waste Nitric Acid Production Technologies", Monograph
ENV/WP.2/5/Add.lO.
Nitric Acid, ISIC 3512, Fertilizer, End Gas Reduction
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***** DOCNO: 400-048-A-237 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
Continuous absorption of SiF4 from waste gas reduces discharges of purified
waste gas.
Manufacture of Fertilizers and Pesticides/ISIC 3512
Zentnun Fur Umweltgestaltung
Schnellerstrasse 140
DDR- 1190 Berlin
German Democratic Republic
The company performs continuous absorption of fluorine - containing waste
gas. This low-waste technology is a continuous method for absorption of
SiF4 from waste gas of the phosphate-fertilizer industry. It works upon the'
principle of turbogrid absorption. In an absorption tower, the waste gas is
cleaned of fluorine streams through several, specifically-designed turbogrid
trays, one after the other.
These turbogrid trays are sprayed with aqueous hexafluorosilicic acid. In
the turbogrid trays, stable dynamic bubbling layers develop which offer a
big mass-transfer surface for the absorption.
Waste gas of the phosphate fertilizer industry (especially superphosphate
industry)
Purified waste gas
Not reported
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
Not reported
Not reported
Not reported
Not reported
Not reported
The quantity of filter-wet sludge amounts to approximately 30 kg per 1
metric ton of P^j superphosphate (20 percent solids - SiCy, 80 percent
adhesive liquids - some 10 to 15 percent H^SiF,,;, remainder H2O). With
low-waste technology there is a discharge of 20 to 30 mg/m3 purified waste
gas, whereas the conventional technology had 1,000 mg f/m3.
Prior to the introduction of turbogrid absorption of fluorine-containing waste
gas, the superphosphate factories of the German Democratic Republic
applied conventional spray-roll chambers for depositing SiF4 from waste
gas. These chambers had the disadvantages of discontinuous operation and
of a maximum efficiency of 90 percent due to limited contact surface; thus
up to 1,000 mg F/m3 were emitted. In order to maintain even this
inadequate efficiency, frequent and very high manual cleaning expenditures
2-69
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CITATION/PAGE:
KEYWORDS:
were required for regularly removing the silicic acid deposited in the
chambers which became extremely hard.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Continuous Absorption of
Fluorine-Containing Waste Gas", Monograph ENV/WP.2/5/Add.48.
Fertilizer, Absorption, ISIC 3512
2-70
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***** DOCNO: 400-01 l-A-202 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGSr
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Nitrophosphate process conserves steam and oil and improves efficiency in
fertilizer production.
Complex Fertilizer or NP/NPK industry/ISIC 3512
Horsl: Hydro a.s, P.O. Box 2594 Solli, Oslo 2 - Norway
The company uses the Nitrophosphate (ODDA) process with conversion of
calcium nitrate and recirculation of nitrogen and phosphorous effluents.
The nitrophosphate process includes nitric acid digestion of phosphate rock
and deep cooling precipitation of calcium nitrate with subsequent conversion
into fertilizer products. The nitrophosphate process includes the use of
waste CO2 from an NH3 plant and avoids the use of sulfur. 1.1 tons of
steam and 35 kg of oil is saved per ton of PjOj by this process. A wide
range of commercial phosphate rocks may be used in the process. The
Norsk Hydro Nitrophosphate products are not subject to self-sustaining
decomposition.
Not reported
Not reported
Not reported
$1,000,000
Not reported
Not reported
Not reported
Not reported
Not reported
The Nitrogen efficiency of the process is 98-99 per cent, the P20S efficiency
better than 99 percent and the KjO efficiency better than 99.8 percent.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of NPK Fertilizers Through the
Nitro-Phosphate (ODDA) Process with Conversion of Calcium Nitrate and
Recirculation of Nitrogen and Phosphorous Effluents", Monograph
ENV/WP.2/5/Add.ll.
Fertilizer, ISIC 3512, Nitrophosphorous, Urea, Ammonia
2-71
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***** DOCNO: 400-062-A-243 *****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Raw material needs and wastewater production decrease using evaporator
system.
Fertilizer Industry/ISIC 3512, SIC 2873
NPK fertilizers, a nitro-phosphate type fertilizer, is produced through the
Norsk-Hydro-ODDA technology. This technology has been modified to
incorporate an effective wastewater evaporator system which reduces the
amount of contaminated cooling water discharge. The wastewater passes
through a series of evaporation steps whereby the vapors are used as wash
water in the calcium carbonate filters and the concentrated solution is
pumped to the neutralizes where it is mixed with the acidic NP solution
and used to regulate the N/P2OS nutrient ratio of the fertilizer. Through this
modified technology, steam and electric energy consumption increases
somewhat but such increases are balanced by the more effective utilization
of nitrogen and the reduction of the wastewater stream discharge.
Phosphate rock, Ammonia, Nitric Acid, Potassium Chloride
Wastes produced include wastewater, NH«NO3, SiF4, NH3 and flue gas.
Aqueous
50 million forints
Not reported
Not reported
Savings in raw materials and water are five times grater than the added cost
of steam and energy.
Eliminates wastewater discharge
The evaporator, used for the elimination of wastewater, can also be applied
for the reduction of waste streams of low salt concentration in various
sectors of the chemical industry.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Wastewater Evaporation Process For
Fertilizer Production Technology", Monograph ENV/WP.2/5/Add62.
Fertilizer, Ammonium Vent Gas, ISIC 3512, SIC 2873, Wastewater
Evaporation
2-72
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***** DOCNO: 400-Q29-A-218 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST: '
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Recovery of ammonia reduces emissions and raw materials requirements in
fertilizer production.
Fertilizer Industry/ISIC 3512
Ministere de 1' Environment et due Cadre de Vie
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
August 1980
The company performs ammonium nitrate synthesis accompanied by
recovery and recycling of the ammonia contained in the vapor. The
synthesis of ammonium nitrate is carried out in both techniques through a
nitric acid reaction on the ammonia. When the reaction takes place, vapor
is formed, containing a small amount of ammonia. Whereas in the formerly
used process the vapor was discharged, it is now washed in nitric acid,
which permits recovery and recycling of the ammonia that it contains.
Ammonia
Vapor containing nitrate and ammonia.
Vapor
(1976 Francs)
F 350,000
Not reported
Not reported
Not reported
Not reported
Reduced production of waste nitrogen by 75%.
Reduced waste nitrogen production and reduced virgin ammonia
requirements.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recovery and Recycling of Ammonia
Contained in Gases from Ammonium Nitrate Production", Monograph
ENV/WP.2/5/Add 29).
Ammonium Nitrate, ISIC 3512, Recovery
2-73
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FQOD
Vegetable Processing
Animal ^and Poultry Processing
' -- . baity Products
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Vegetable Processing
***** DOCNO: 400-043-A-232 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Wastewater treatment results in recovery of methane. ;
Food and Fermentation Industries/ISIC 3111, 3112, 3113, 3114, 3118,
3131, 3132, and 3133
AB Sorigona
Box 139, S-24500
StafTenstorp, Sweden
Wastewaters from the industry are treated with anaerobic microorganisms
for recovery of methane. The water treated in this way is then treated with
aerobic microorganisms for achieving a very good effluent quality.
The aerobically-produced excess biosludge is recycled back to the anaerobic
step. The recovery of methane is about 300 I/kg COD treated.
Industrial effluents containing large amounts of biodegradable organic
material (e.g., wastewaters from food and fermentation industries).
Crude digestion gas, small amounts of excess sludge.
Aqueous
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "The Ahamet Process for Wastewater
Purification', Monograph ENV/WP.2/5/Add.43.
Activated Sludge, Methane, Ahamet Process, ISIC 3111
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*****DOCNO: 453-001-A-OOO *****
1.0 Headline: Recovery and use of methane from sugar beet processing effluent
2.0 SIC Code: SIC 2063, Beet Sugar
3.0 Name and Location of Company:
British Sugar pic
Oundle Road
Peterborough PE2 9QU, England
4.0 Clean Technology Category:
This technology uses an anaerobic stage to recover methane from sugar beet effluent for use as a process
fuel.
5.0 Case Study Summary
5.1 Process and Waste Information: The facility processes sugar beets generating a wastewater effluent
with a high chemical oxygen demand. Traditionally, this effluent was dealt with aerobically by a
water treatment plant and its organic content wasted. The clean technology was to add an anaerobic
stage to the water treatment section to convert the organic content of the effluent to usable methane.
The fermentation takes place in the digestion vessel, the off-gas consists largely of methane with
some carbon dioxide. Key features of the process are the pre-heating of the incoming stream using
low-grade heat, careful control of the pH and the recirculation of sludge. The methane provides
process heat to dry the pulp for use as an animal feed.
5.2 Scale of Operation: British Sugar operates 12 beet factories and employs 3,000 people. The
Peterborough facility produces 100,000 tons of sugar per year.
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: No information provided.
5.5 Material/Energy Balances and Substitutions: No information provided.
6.0 Economics:* It is assumed that the economics cited in the source document are on a per plant basis and
not the total of all 12 British Sugar plants.
6.1 Investment Costs: The capital cost of the technology is 750,000 English Pounds.
6.2 Operational and Maintenance Costs: Annual savings in lower sewage charges are 26,000 English
Pounds and 8,000 English Pounds in electricity cost savings. The value of recovered gas is 25,000
English Pounds.
6.3 Payback Time: Payback time is 12 years.
7.0 Cleaner Production Benefits
The technology resulted in reduced chemical oxygen demand in the wastewater effluent. Recovery and use
of methane from organic matter in the wastewater effluent were achieved. Lower operating costs and
energy conservation were added benefits of the technology.
2-75
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8.0 Obstacles, Problems and/or Known Constraints
None were identified.
9.0 Date Case Study Was Performed
Unknown
10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication.
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p. 21.
10.3 Level of Detail of the Source Material: No additional detail is provided.
10.4 Industry/Program Contact and Address: Mr. J.N. Smith, Chief Safety and Environment Officer,
British Sugar pic, Oundle Road, Peterborough PE2 9QU, England, Telephone (0733) 63171.
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Chemical oxygen demand, wastewater effluent, sugar beet processing effluent
11.2 Process type/waste source: Sugar products, agricultural processing
11.3 Waste reduction technique: Anaerobic digestion
11.4 Other keywords: Methane, United Kingdom, SIC 2063
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chemical Oxygen Demand, Wastewater Effluent, Sugar Beet Processing Effluent, Sugar Products,
Agricultural Processing, Anaerobic Digestion, Methane, United Kingdom, SIC 2063
2-76
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***** DOCNO: 400-041-A-230 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLCX3Y DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:.
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SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Eluates from beet juice demineralization are recovered and sold as fertilizer
and animal feed.
Food Industry/ISIC 3118
Ministere de 1'Environnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The company demineralizes beet juice with valorization eluates. The
demineralization eluates are separated from the other effluents. After
having been homogenized, these eluates are concentrated by evaporation and
then crystallized. Centrifugation permits the separation of salts that are
marketed as fertilizer and the mother liquor, rich in proteins, that is
marketed for animal feed.
Beet juice, salt
Not reported
Not reported
(1973 Francs)
F 3.0 million
12 Francs/ton demineralized beets
Not reported
Not reported
Not reported
Not reported
This process is more reliable than a standard purification process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Demineralization of Beet Juice with Re-Use
of Eluates", Monograph ENV/WP.2/5/Add.41.
Foodstuff, Beets, Demineralization, ISIC 3118
2-77
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***** DOCNO: 400-084-A-255*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
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IMPACT:
CITATION/PAGE:
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Potato starch extracted without water washing eliminates wastewater
generation.
Food Manufacturing/ISIC 311
Extraction of potato starch without water washing of the finely divided
potatoes. The potatoes are separated into solid and liquid phases, which are
then processed independently.
Five tons of potatoes, 0.2 GJ of electric power and 0.1 GJ in the form of
steam, per ton of potato powder.
Wastewater
Aqueous
0.2 million rubles for new process.
380 rubles per ton of potato powder.
Not reported
0^4 million rubles in initial investment, due to need for water-treatment
station in conventional process. ISO rubles savings per ton of starch
produced due to reduced operating costs.
None
In the low-pollution technique, the water required is 3.5 m3 per ton of
end-product compared to 14.5 m3 in the conventional process.
Elimination of wastewater generated from wash water and internal
vegetation water in the standard starch process. In the low-pollution
process of potato powder production, one obtains undiluted potato cell fluid
which undergoes direct processing.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Dry Extraction of Potato Starch Substitute",
Monograph ENV/WP.2/5/Add84.
Wastewater Treatment, Food Processing, Potato, Starch, ISIC 311
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***** DOCNO: DOCUMENT NOT AVAILABLE*****
1.0 Headline: Recovery of Protein from Potato Starch Effluent Using Reverse Osmosis
2.0 SIC/ISIC Code: 2046
3.0 Name and Location of Company:
Avebe Foxhol, Foxhol, The Netherlands
4.0 Clean Technology Category: This technology uses reverse osmosis to concentrate potatofruitwater to a
level that the protein can be recovered economically using coagulation. Reverse osmosis is a process that
separates water from dissolved and suspended solids by forcing water through the membrane while
dissolved substances are retained. The filtrate from the reverse osmosis process is recycled within the
factory to further reduce process water intake. The plant also implemented a counter current extraction
process that further reduced water usage.
The reverse osmosis process, aside from reducing water usage and wastewater discharge, also produces
two saleable products. Following concentration of die potato water, protein is extracted from the
concentrated reverse osmosis stream by steam coagulation and dried. The residual potato water is
evaporated and used for the enrichment of the potato fibers and incorporated in cattle feed.
5.0 Case Study Summary:
5.1 Process and Waste Information: Potato starch production involves washing and grinding potatoes
to produce a pulpy liquor of potatofruitwater, starch, and fibers. Starch is extracted, with fibers
separated using centrifuges. The residual waters contain protein, sugar, and minerals at a
concentration previously too dilute to recover. The new technology uses a reverse osmosis open-
channeled tubular membranes to separate water from dissolved and suspended solids. The process
generates two streams: a concentrated liquor and clean water.
5.2 Scale of Operation: The clean technology was implemented at a plant processing 180,000 tons of
potatoes an hour and previously produced 2.2 million cubic meters per year of potato water.
5.3 Stage of Development: The process was implemented full scale at Avebe Foxhol.
5.4 Level of Commercialization: The reverse osmosis is available from PCI Membranes Systems Ltd.,
a specialist in membrane filtration equipment with 25 years experience.
5.5 Material/Energy Balances and Substitutions:.
Material Category Quantity Before Quantity After
Water Usage 7 nrVton potato 0.6 mVton potato
Wastewater Generation 3.2 million mVyr 1.1 million mVyr
6.0 Economics*
6.1 Investment Costs: Not Specified.
6.2 Operational and Maintenance Costs: The overall cost to Avebe of concentrating the liquor with
reverse osmosis was approximately US$0.54 per m3 of potato water treated.
6.3 Payback Time: Not Specified.
2-79
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7.0 Pollution Prevention Benefits
The reverse osmosis system provides for; major reductions in the volume of process water consumed,
reduction in capital and energy as a result of the reduction in the quantity of water handled enabling the
heat coagulation and evaporation plant to be half the size, and the production of two by-products from the
effluent. This also solves an effluent treatment problem (including calming the public outcry about strong
odors and killing water life) and avoids wastewater disposal costs.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: Late 1970's early 1980's.
10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Recovery of Protein from Potato Starch
Effluent," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mr Wijnholds, Avebe Foxhol, Avebeweg 1, 9607 PT
Foxhol, The Netherlands, Tel: +31 5980 42136 •
Miss N J Randies, Business Development Manager, PCI Membrane Systems Ltd, Laverstoke Mill,
Whitchurch, Hampshire RG28 7NR, United Kingdom, Tel: =44 256 896966
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Potato Starch Manufacturing
11.3 Waste Reduction Techniques: Recycling
11.4 Other Keywords: Reverse Osmosis
11.5 Country Code:
12.0 Assumptions
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Potato Starch Manufacturing, Recycling, Reverse Osmosis
2-80
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***** DOCNO: 400-039-A-228 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Coagulation and centrifugation of vegetation water recovers proteins.
Food Industry/ISIC 3121
Ministere de rEnvironnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, Fiance
The company performs extraction of potato starch with recovery and
valorization of proteins in internal vegetation water. Coagulation followed
by centrifugation of the proteins contained in the internal vegetation water
permits them to be separated from the water whereas with the standard
technique the vegetation water, still full of proteins, was discharged into the
river after having been stored for a month.
Internal vegetation water
Wash water and manufacturing water.
Aqueous
FF 8.6 million
Not reported
Not reported
Not reported
Not reported
The discharge flow, 17.5 mVton of potato starch, remains the same, but the
pollution is reduced by about 40 per cent. The biochemical oxygen demand
is 70 kg/ton and the chemical oxygen demand is 145 kg/ton compared to
120 kg/ton and 205 kg/ton, respectively, in the standard process.
Although this technique is already operational it may still undergo
improvements that will permit an increase in the efficiency of the recovery
and valorization of the products recovered.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Extraction of Potato Starch with Recovery
and Use of Proteins in Internal Liquid", Monograph ENVAVP.2/5/Add.39.
Foodstuff, ISIC 3121
2-81
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***** DOCNO: 400-035-A-224 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Use of abrasive peeling machine reduces material requirements in
processing tubers.
Manufacturing of Foodstuffs, Drinks and Tobacco/ISIC 3113
Ministere de PEnvironnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
In the low pollution technique the washed tubers are peeled in an
peeling-machine composed of abrasive rolls, with water. The wastewater
containing peelings is filtered and recycled at the peeling stage. The filter
contains only peelings of less than 5 mm and it is periodically cleaned.
In the standard technique the washed tubers are dipped into a soda solution,
then peeled and dipped into a citric acid solution for neutralization.
In the low pollution technique, material requirements are substantially
reduced: water needs are down from 25 m3 to 5 m3 per ton of tubers
treated, no soda is used (as opposed to 10 kg/ton) and citric acid use is
down from 6 kg per ton in the standard technique to 1 kg per ton.
Fruits and vegetables
Fruit and vegetable peelings
Not reported
Not reported
Not reported
Not reported
Not required
Water requirements reduced by 20 of /ton of tubers, reduced citric acid
usage, and eliminates soda usage.
The wastes produced by the low pollution technique are made of tuber
wastes and citric acid which are contained in the water discharged.
Peelings retained by the filter are sent for dumping. For each ton of tubers
treated, 5 m3 of wastes are produced, which contain 15 kg of tuber wastes
and 1 kg of citric acid; 170 kg of peelings are sent for dumping.
Apart from pollution reduction, the low pollution technique ensures an
improved output, higher quality of products, and a reduction in raw
materials.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Mechanical Peeling of Vegetables/Fruits",
Monograph ENV/WP.2/5/Add.35.
Foodstuff, Abrasives, ISIC 3113
2-82
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Animal and Poultry Processing
***** DOCNO: 400-051-A-240 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Centrifugation used to recover fats from pate* production.
Manufacturing of Food, Beverages and Tobacco/ISIC 31
Ministere de 1'Environnement
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92522 Neuilly-sur-Seine Cedex, France
The company manufactures preserved pate's with recovery of fats by
Centrifugation. Pork fats are cooked in water circulating in a closed circuit. '
The cooking water which is normally rejected every day, is centrifuged.
Other liquid effluents from washing equipment, floors, etc., go through a
fat separator. In the standard technology there is no centrifuge. Polluted
water is discharged from the fat separator.
Not reported
Wastewater from the fat separator.
Aqueous
Not reported
Not reported
Not reported
Not reported
Not reported
The water resulting from cooking is equal to 285 liters per ton' of pate*,
containing: 2 kg of fats; biochemical oxygen demand, 3.5 kg; chemical
oxygen demand, 8 kg (versus respectively, 285 liters, 10 kg, 10 kg, 20 kg
with the standard technology).
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Manufacture of Preserved Pat£s with
Recovery of Fats by Centrifugation", Monograph ENV/WP.2/5/Add.51.
Foodstuff, Fat Recovery, Centrifugation, ISIC 31
2-83
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***** DOCNO: 400-078-A-311*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST*
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACTS:
CITATION/PAGE:
KEYWORDS:
Recovery of animal fats reduces wastewater generation by 90% and reduces
energy costs.
Manufacture of Food, Beverages and Tobacco/ISIC 31
Manufacture of fats by continuous melting process with recovery of fats and
protein from wastewater. Tallow is ground and melted in a steam-fed
melting pot. Extracted fats are refined. Process water is treated in a
concentrator to further recover fats and proteins. Concentrates are
dehydrated and together with the grease can be sold as animal feed. The
evaporated process water is condensed before being reused. In the standard
technology, the process wastewater is degreased, processed through a
florentine flask, and discharged.
Water, steam, tallow
Wastewater
Aqueous
FF 795,000 (1979 figures)
FF 14 per ton of tallow (1979 figures)
Not reported
Not reported
200 liters of water per ton of tallow.
For each ton of tallow processed, the wastewater generation is reduced from
5001 for the standard technology to 501 for the modified technology. The
energy required for processing wastewater with the modified process is 670
MJ versus 21 MJ with the standard process. Also, with the low-waste
technology, it is possible to recover 5.7 kg of proteins per ton and 3 kg of
animal fats per ton of tallow.
The volume and the quality of wastewaters in terms of BOD and COD
concentrations are improved significantly by the modified process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Manufacture of Fats by Continuous Melting
with Recovery of Fats and Proteins from the Wastewater", Monograph
ENV/WP.2/5/Add.78.
Food Processing, Fat Recovery, Condensates, Wastewater, ISIC 31
2-84
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***** DOCNO: 450-013-A-001 *****
1.0 Headline: Poultry slaughterhouse decreases effluent by using dry suction system for clean-up
2.0 SIC Code: 2015
3.0 Name and Location of Company
La Cooperative Federee de Quebec,
Saint-Felix-de-Valois, Quebec.
4.0 Clean Technology Category:
This technology involves wastewater reduction by installing a vacuum system to clean-up poultry organs
from cutting tables.
5.0 Case Study Summary
5.1 Process and Waste Information: Water is an essential element for poultry slaughterhouses. It is
used to clean poultry cages, to scald the poultry so that feathers may be removed, to wash feathers
from poultry, to remove organs from cutting tables, to refrigerate poultry, and to wash equipment.
The authorities at the municipal water treatment system of Quebec found that the efficiency of their
purification machinery was being greatly compromised by the volume and high pollution levels of
water from the poultry slaughterhouses. As a result, the water treatment company and La
Cooperative Federee decided to treat the slaughterhouses^ waters on site. The company elected
to decrease the amount of water it was using and, therefore, avoid the $1,500,000 cost of a
treatment system. The most obvious way to decrease the volume of water at the facility was to
install a vacuum system that sucked organs and other inedible body parts from the visceration tables
and collected them in a vat of other non-edible parts. The old system used a lot of water to hose
the tables down with disinfectant. As a result of the new suctioning system, the company was able
to reduce the pollutants in its effluent by 75%. The company also used the following source
reduction techniques to decrease its wastewaters:
*Recovered blood instead of washing it away,
*Segregated process waters from rain waters so that only the volume of process waters needing
treatment would be discharged to a pit,
*Installed automatic spray nozzles to concentrate water more directly when washing equipment,
*Installed high pressure cleaning systems to clean more efficiently.
5.2 Scale of Operation: La Cooperative Federee slaughters approximately 23,000 poultry per day. It
used 500,000 liters/water/day and discharged 400 kg BOD(5)/day (demande biochimique en
oxygen).
5.3 Stage of Development: This technology was fully implemented at the time of this case study.
5.4 Level of Commercialization: This technology was fully available at the time of this case study •
although the suction system needed to be specifically designed for this application.
2-85
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5.5 Material/Energy Balances and Substitutions
Transportation of Visceral Organs
Parameters (kg/ton)
BOD(5)
Suspended Solids
Oils and Fats
Traditional
Transportation
Transportation by Water
without hens*
15.5
10.9
5.1
Transportation at La Cooperative
Transport by Water
w/o hens*
17.1
9.7
3.7
with hens*
39.5
25.8
7.0
Suction System
w/o hens*
8.2
7.8
2.1
with hens*
11.0
9.4
2.5
* It is noted in the text that hens pollute more than other poultry due to the eggs located in the viscera.
6.0 Economics'1'
6.1 Investment Costs: In order to install the equipment for the suction system, the company invested
$180,000 compared to the $1,500,000 the company would have had to spend to install a chemical
and biological treatment system,
6.2 Operation and Maintenance Costs: With the dry suction system, the company must only spend
$4,000/year for disinfection chemicals as opposed to spending $ 10,000/year on chemical and energy
costs for the chemical/biological treatment system:
6.3 Payback time: The payback time of this operation was 7 months.
It is assumed that costs are reported in Canadian dollars.
7.0 Cleaner Production Benefits:
This process reduced the wastewaters of the slaughterhouse by 75%. The use of disinfection chemicals
decreased by 75% and oils and fats in the effluent were reduced by 65%.
8.0 Obstacles, Problems and/or Known Constraints
One of the obstacles the company had to overcome was how to implement a suction system using existing
pipes and equipment. The company was able to attach the system to existing conduits to transport the
organs to an existing storage area for inedible parts.
9.0
10.0
Date Case Study Was Performed: This case study was performed in 1986.
Contacts and Citation
10.1 Type of Source Material: Report
10.2 Citation: Secteur Agro-Alimentaire. Technologies Propres. Abattage de Volailles. Gouvernement
de Quebec, Ministre de rEnvironnement, Gestion et Assainissement des Eaux, May 1989. Source
document is in French.
2-86
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10.3 Level of Detail of Source Material: More detail is provided about the slaughter industry in general
in Quebec. More detail is also provided about the system before the changes and the system after
the implementation of the suction system.
10.4 Industry/Program Contact and Address: Regional offices, addresses and phone numbers are given
on the back of the report.
10.5 Abstractor Name and Address: Blair M. Raber, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, VA, 22043.
11.0 Keywords
11.1 Waste Type: Wastewater, Food Wastes, Animal and Marine Fats, Fats and Oils.
11.2 Process Type/Waste Source: Food Processing.
11.3 Waste Reduction Technique: Equipment Modification, Process Modification, Source Reduction,
Wastewater Reduction, Jet Sprayers, Vacuum System.
11.4 Other Keywords: Agriculture, Annual Cost Savings, Canada, Environmental Impact Reduction,
Food Products.
(*) Disclaimer - Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Food Wastes, Animal and Marine Fats, Fats and Oils, Food Processing, Equipment
Modification, Process Modification, Source Reduction, Wastewater Reduction, Jet Sprayers, Vacuum System,
Agriculture, Annual Cost Savings, Canada, Environmental Impact Reduction, Food Products
2-87
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Dairy Products
***** DOCNO: 452-002-A-OOO *****
1.0 Headline: Disposal of wastewaters and decreased water requirements are achieved through conservation,
recycling and process modification in dairy operations
2.0 SIC Code: 2202 Cheese Manufacturing
3.0 Name & Location of Company: General information presented with no mention of specific companies or
facilities.
4.0 Clean Technology Category
Technology Principle: This technology involves minimizing water consumption and subsequent wastewater
production through onsite conservation and recycling while also increasing productivity.
5.0 Case Study Summary
5.1 Process and Waste Information: This new waste technology is concerned with water, which is a
universal solvent in many processes and subsequently becomes an environmental problem. This
technology focuses on eliminating the need for new water in a process by recycling water into the
process and minimizing consumption. Cheese manufacturing was the example presented. Cheese
manufacture produces two wastewater streams: the whey and the water from cleaning the plant.
Whey can go to an uitrafiltration plant to produce protein and permeate powder and wastewater can
be recycled. Total recycle begins with good preparation including initial treatment of water to
remove any contaminants such as hardness, inorganic or organic substances through hyperfiltration,
and a complete clean out of the plant to eliminate on-site contaminants (i.e., left-over bacteria).
The process water is conserved by installing better-built pumps, i.e., better glands and bearings
independent of the motor, preventing release onto the floors. Discontinuous operation is replaced
with continuous operation which serves to increase water economy with minimum storage capacity
required. In addition, production increases with less investment. Plants must be set up or run to
ensure that total shut-down is not required for clean-up, and a phased clean-up can be effectually
conducted with all flush water being reused or directed to uitrafiltration plants which recover almost
all internal protein as product.
The final step is to acknowledge that no stream is a waste stream and must be handled in sanitary
way. Stream segregation is important as it permits less complicated treatment or regeneration
processes. In a dairy plant wastewater streams contain thermophiiic and spore-forming
microorganisms and recirculation of this water can only be achieved if organism build-up
prevention is practiced. Necessary precautions require that water be stored with cleaning agents
to prevent the growth of such organisms or be stored with a very low content of BOD and
nutrients. BOD and nutrients can be removed through the use of hyperfiltration. Cleaning agents
are also necessary. Nitric and phosphoric acids and sodium hydroxide, and some complexing
agents can all be recovered (except what has been neutralized), and uitrafiltration of these agents
is a good way to remove proteins for animal feeds.
It was mentioned that these strategies have been introduced successfully into a pulp and paper
factory in Kai Shan Tun in the Jilin Province in China. This plant recovers lignosulphonate from
sulfite liquor using uitrafiltration. The lignosulphonate is used for paper gluing.
5.2 Scale of Operation: Specific plants or facilities were not mentioned however, the example given
represented a commercial cheese manufacturing process line.
2-88
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5.3
5.4
5.5
State of Development: This technology is fully developed.
Level of Commercialization: The example given represented a commercial cheese manufacturing
run.
Balances and Substitutions: Water is treated before use and is conserved and regenerated
throughout the cheese manufacturing process to effectively reduce the amount of new water
required and eliminate wastewaters requiring disposal.
Specific amounts were not given.
6.0 Economics: The investment costs in a dairy operation where wastewaters are not produced are higher than
those of a conventional process (due to hyperfiltration plants etc.) however, advantages include: almost all
product ends up as valuable product; most cleaning chemicals are recovered; the amount can be reduced
to 20-30% of the normal consumption; water consumption is minimized; no money is spent for wastewater
treatment.
6.1 Investment Costs: Specific investment costs were not reported, although it was mentioned that
investment costs for nonwastewater dairy plants were higher than conventional dairy plants.
6.2 Operational and Maintenance Costs: Specific costs were not mentioned; however, it can be
assumed that savings can be realized with the reduction of cleaning agents and required water due
to conservation and recycling, as well as, a reduction in wastewater treatment costs. Profit is also
realized in the production of permeate powder and proteins from the hyperfiltration plants.
6.3 Payback Time: Payback time was not discussed although the benefits of recycling can be seen
immediately.
7.0 Cleaner Production Benefits
Economic benefits are seen in a reduction of cleaning agents and water purchased, the production of
proteins and permeate powder, a reduction in wastewater disposal costs, and an increase in productivity due
to increased operating hours.
Regulatory compliance is easier with significantly reduced volumes of waste requiring hazardous waste
disposal.
8.0 Obstacles, Problems and/or Known Constraints
The buildup of thermophilic and spore forming microorganisms in plant waters is a problem and must be
controlled through additives and controlled storage. Water must be treated prior to use to eliminate the
introduction of contaminants into plant waters.
9.0 Date of paper preparation was not provided.
10.0 Contacts and Citation
10.1 Type of Source Material: Paper presented at a Non-waste technology symposium held in Finland.
10.2
10.3
Citation: Madsen, Erik Rud, "Water and Raw Materials for Non-Waste Technology Processes",
Technical Research Center of Finland. Espoo Finland, June 20-23, 1988, (51-62).
Level of Detail of Source Material: Source material was designed to present general strategies
rather than specific technical information.
2-89
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10.4 Industry/Program Contact and Address: Rud Erik Madsen, A/S De Danske Sukkerfabrikker,
Nakskov, Denmark.
10.5 Abstractor and Address: Susan Wojnarowski, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, VA 22043
11.0 Keywords:
11.1 Waste Type: Wastewater, Rinsewater, Whey
11.2 Process Type/Waste Source: Cheese manufacturing, SIC 2202
11.3 Waste Reduction Technique: Reclamation, Recovery, Rinsewater Reuse, Spill Control,
Conservation, Filtration, Process Control.
11.4 Other Keywords: Hyperfiltration Plant, Denmark
Keywords: Wastewater, Rinsewater, Whey, Cheese Manufacturing, SIC 2202, Reclamation, Recovery, Rinsewater
Reuse, Spill Control, Conservation, Filtration, Process Control, Denmark
2-90
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***** DOCNO: 450-Q10-A-001 *****
1.0 Headline: Gheese manufacturer chooses source reduction over implementing a secondary biological
treatment system to comply with effluent standards
2.0 SIC Code: 2022
3.0 Name and Location of Company
La Fromagerie de la Cooperative Agropur, Fromagerie d'Oka, Oka, Quebec, Canada
4.0 Clean Technology Category: This technology involves a facility-wide reorganization and modification of
every step of cheese production.
5.0 Case Study Summary
5.1 Process and Waste Information: The production of cheese at La Fromagerie is divided into 5
stages. All of these stages were scrutinized and ways were found to decrease the amount of
pollution at all levels of production.
*Milk Receiving: In order to eliminate the wasting of milk in the storage silos, a squeegee is used
to squeeze out the excess. In addition, high-powered water jets reduce the amount of water used
to clean the equipment.
*Pasteurization: To eliminate the wasting of milk and to decrease the volume of washing and
disinfecting solutions, the company adjusted the dimensions of the stopper and the pasteurizer to
allow pasteurization to occur in the tubs on a continual basis.
*Cheese making: To recover minute panicles of cheese, cotton filters were used. To recover
cheese from the floor, rubber scoops and brooms were used. To recover residues of cheese from
the cleansing process, they are scooped up by hand. To reduce the rinsewaters and disinfection
solutions in the food conduit from the tables, fixed conduits were replaced with rotary conduits.
To recover lactoserum from the first rinsing of the conduits, the stock reservoirs are pumped. To
recover milk and the rinses of the food conduits from the tubs, a conductivity meter is used.
*Molding the Cheese: To recover lactoserum, collection pipes are used.
""Disinfection: To eliminate phosphorous, products containing phosphorous were not used.
Scale of Operation: Not Available
5.2
5.3
•5.4
5.5
Stage of Development: This technology is fully implemented and the quantitative figures noted
throughout the text are based on actual production.
Level of Commercialization: This technology is fully commercialized.
Material/Energy Balances and Substitution
Material Category Before
Purity of effluent 80%
Reduction in Phosphorous Loss N/A
Loss of Milk 9%
Recovering fine particles
of cheese 0
After
98%
93%
2%
50 kg/day
2-91
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6.0 Economics*
6.1 Investment Costs: The company had a choice between implementing a secondary biological
treatment system or reducing pollutants at the source. By choosing source reduction, the company
saved $270,000 as illustrated below.
Capital Costs
Operation Costs
Energy Costs
Secondary Biological
Treatment
$350,000
$20,000
$6,250
Source Reduction
$80,000
$0
$0
6.2 Operational and Maintenance Costs: Since the changes made are at the source and are one-time
changes, there are no operation costs.
6.3 Payback Time: Not Available
It is assumed cost data was reported in Canadian dollars
7.0 Cleaner Production Benefits: This process dramatically reduced the amount of pollutants in the effluent
and increased production since cheese that would otherwise have been lost is reclaimed and put back into
the manufacturing process.
8.0 Obstacles, Problems and/or Known Constraints: Not Available
9.0 Date Case Study Was Performed: These pollution prevention measures were initiated in 1985.
10.0 Contacts and Citation
10.1 Type of Source Material: Report
10.2 Citation: Secteur Agro-Alimentaire. Technologies Propres. Production Fromagere. Gouvemement
du Quebec, Ministre de l'Environnement, Gestion et Assainissement des Eaux, Revised June 1988.
Source document is in French.
10.3 Level of Detail of the Source Material: More detail is provided about the cheese industry in
Quebec and diagrams illustrate how the equipment is used differently before and after the changes.
10.4 Industry/Program Contact and Address: Regional offices, addresses, and phone numbers are given
on the back of the report.
10.5 Abstractor Name and Address: Blair M. Raber, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, VA 22043
11.0 Keywords
11.1 Waste Type: Dairy wastes
11.2 Process Type/Waste Source: Cheese, Agriculture, Food and Kindred Products, and Food Products.
11.3 Waste Reduction Technique: Alternatives Evaluation, Food Processing, Food Preparations,
Lactoserum recovery, filtration, material conservation.
11.4 Other Keywords: Canada, Increased Productivity, Increased Efficiency, Process Efficiency.
2-92
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(*) Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Dairy Wastes, Cheese, Agriculture, Food and Kindred Products, Food Products, Alternatives
Evaluation, Food Processing, Food Preparations, Lactoserum Recovery, Filtration, Material Conservation, Canada,
Increased Productivity, Increased Efficiency, Process Efficiency
2-93
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***** DOCNO: 400-050-A-239 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Recovery of lactoserum powder and heat reduces emissions.
Manufacture of Food, Beverages and Tobacco/ISIC 31
Ministere de 1'Environnement
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92522 Neuilly-sur-Seine Cedex, France
The company produces lactoserum powder with recovery of powder and
heat from the discharged air. In both techniques, the lactoserum is injected
into the drying tower where hot air(180°C) circulates. The lactoserum is
recovered at the tower base. The outgoing hot air, loaded with powder, is
used for pre-heating the incoming air and then washed with enriched hot
lactoserum in order to recover lactoserum particles. With the standard
technique, the air simply goes through two hydrocyclones and is discharged
hot and heavily loaded with particles.
Liquid lactoserum
Emissions to the atmosphere have the following characteristics: particles:
3 kg per ton of powder (versus 10.5 kg). Temperature: 45°C (versus
87° C).
Air
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Lactoserum Powder with
Recovery of Powder and Heat from Discharged Air", Monograph
ENV/WP.2/5/Add.50.
Foodstuff, Lactoserum, ISIC 31
2-94
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IRON AND STEEL:
-------
-------
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Gas Phase Heat Treatment of Metals Using a Fluidized Bed of Alumina
2.0 SIC/ISIC Code: 3398
3.0 Name and Location of Company:
Chartered Metal Industries Pte Ltd, Singapore
4.0 Clean Technology Category: This technology uses a fluidized bed of alumina particles to heat treat steel
parts. A mixture of air, ammonia, nitrogen, natural gas, liquified petroleum gas, and other gases are used
as the fluidizing gas to carry out the heat treatment of the materials immersed in the bed. Hydrocarbon
gases are used for carburizing, ammonia for nitriding and nitrogen for neutral hardening. The bed is
heated by electricity or gas with quenching also performed in the bed. The hot exhaust gases are used for
heat exchange.
5.0 Case Study Summary:
5.1 Process and Waste Information: The heat treatment of steel (i.e., hardening, carburising, and
nitrocarburizing) are processes usually carried out in baths of molten salts, such as nitrates, nitrites,
carbonates, cyanides, chlorides, and caustics. The combination of chemicals and high temperatures
is conducive to explosion, burns, and poisoning. Environmental problems arise from the resulting
vapors and the removal, transport, and disposal of the toxic salts. Quench water, oil, cleaning
water, and washing water had to be neutralized before discharge to the sewer. Off gases had to
be scrubbed before exhausting to the atmosphere. With the new fluidized bed heat treatment
process, there is no salt management necessary nor are there toxic vapors to control.
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: Not Provided.
5.4 Level of Commercialization: The equipment is available from Quality Heat Treatment Pty Ltd, an
Australian company that designs and sells advanced technology heat treatment processing
equipment.
5.5 Material/Energy Balances and Substitutions: No quantitative figures were given but the new
processes does not require salt management and disposal, there is no wastewater treatment
necessary, and there is no need for scrubbing the heat treatment off gases.
6.0 Economics*
6.1 Investment Costs: The capital investment for four fluid beds used to replace their existing salt bath
lines is US$180,000.
6.2 Operational and Maintenance Costs: Using the fluidized bed heat treatment system saves the facility
US$36,000 a year in energy costs and US$51,000 a year in salt and maintenance costs. Costs for
gas and alumina will increase using the fluidized bed, but costs for energy, parts cleaning, salt pot
replacement, waste neutralization, and salt replacement will decrease.
6.3 Payback Time: Approximately 2 years.
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7.0 Pollution Prevention Benefits
The biggest advantages are the reduction in wastewater discharges and the improved working environment.
Additionally, the quality of the product may be superior in many cases to that produced using the older
method.
8.0 Obstacles, Problems, and/or Known Constraints
All forms of heat treatment are amenable to the fluidized bed technique, although austempering is the most
cost effective.
9.0 Date Case Study Was Performed: Not Provided.
10.0 Contacts and Citation
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Gas Phase Heat Treatment of Metals,"
1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mr. Koh Beng Hock, Chartered Metal .Industries Pte Ltd,
249 Jalan Boon Lay, Singapore 2261, Tel: +65 660 7186
Mr. Ray W Reynoldson, Managing Director, Quality Heat Treatment Pty Ltd, Unit 1 18 Turbo
Drive, Bayswater North, Victoria 3153, Australia, Tel: +61 3 720 2744
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater, Molten Salts (including cyanide), Toxic Vapors
11.2 Process Type/Waste Source: Heat Treatment of Metals
11.3 Waste Reduction Techniques: Process Modification
11.4 Other Keywords: Fluidized Bed Heat Treatment
11.5 Country Code:
12.0 Assumptions:
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Molten Salts (including cyanide), Toxic Vapors, Heat Treatment of Metals, Process
Modification, Fluidized Bed Heat Treatment
2-96
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Galvanizing of Steel Using Electromagnetic Application
2.0 SIC/ISIC Code: 3479
3.0 Name and Location of Company:
Delot Process S A, France
4.0 Clean Technology Category: This technology uses induction heating to melt the zinc, an electromagnetic
field to control the distribution of molten zinc, and modem computer control of the process. Raw steel
is fed in automatically continuously or in batches. Surface preparation is performed by controlled shot
blasting, followed by induction heating. The steel then enters the coating chamber where melted zinc in
an inert atmosphere is held in suspension by an electromagnetic field. The speed of the production line
controls the thickness of the zinc coating.
5.0 Case Study Summary:
5.1 Process and Waste Information: Galvanizing is a corrosion protection treatment for steel. The
traditional technique consists of chemically pretreating the steel, then immersing the steel in a bath
of molten zinc. The process also generates a lot of waste and fumes. The new process eliminates
the need for water and provides for more control over the coating quality.
5.2 Scale of Operation: Not Identified.
5.3 Stage of Development: This equipment is developed by Delot Process S A for coilable material.
The company is presently developing the technology to handle rigid steel.
5.4 Level of Commercialization: This system was operated by Delot Process S A. The availability is
not discussed.
5.5 Material/Energy Balances and Substitutions: This new process eliminates wastewater generated in
the older galvanizing process.
6.0 Economics*
6.1 Investment Costs: Not Specified.
6.2 Operational and Maintenance Costs: Lower operating costs result in the coating process being 18
percent of the steel cost compared to 60 percent with traditional galvanizing methods.
6.3 Payback Time: Three years when replacing existing plant.
7.0 Pollution Prevention Benefits
Use of the cleaner technology eliminates wastewater, reduces the amount of zinc necessary to galvanize
the steel, provides for better control of the quality and thickness of the zinc coat, reduces labor
requirements, reduces maintenance, and provides a safer working environment.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: Not Specified.
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10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "New Technology: Galvanising of Steel,"
1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: M Guy Dussous, Managing Director, Delot Process S A,
10/20 Ave des Freres Lumiere, Post box 74, 78194 Trappes, Paris Cedex, France, Tel: +331 30
66 08 78
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Steel galvanizing
11.3 Waste Reduction Techniques: Process modification
11.4 Other Keywords:
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Steel galvanizing, Process modification
2-98
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***** Document No. 453-001-A-OOO *****
1.0 Headline: Fugitive dust recovered and reused in an iron foundry
2.0 SIC Code: SIC 3322, Malleable Iron Foundries
3.0 Name and Location of Company:
Baxi Partnership
Brownedge Road
Bamber Bridge
Preston PR5 6SN, England
4.0 Clean Technology Category
This technology involves recycling fugitive dust back into the manufacturing process.
5.0 Case Study Summary
5.1 Process and Waste Information: Precision iron founding involves the production of moulds and
cores from mixtures of sand and clay. In the traditional process, the factory space is ventilated by
extractor fans. If scrubbers are used, the dust forms a sludge which is dumped at high cost.
At this foundry, the dust collected as sludge by water scrubbers is recovered by returning it to the
mixer to make new moulds. A special sludge pumping system uses a centrifugal pump with a
natural rubber impeller to overcome the problems associated with the abrasive properties of the
sludge. The composition of the moulding material is controlled by using a highly effective and
flexible electronic control and display system.
5.2 Scale of Operation: The facility has 400 employees on a 15 acre site. Over 25,000 tonnes of cast
iron are melted per year using two 4MW electrical furnaces.
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: Unknown.
5.5 Material/Energy Balances and Substitutions: The system recovers 1600 te per year of sludge.
6.0 Economics*
6.1 Investment Costs: The capital investment was 19,000 English Pounds.
6.2 Operational and Maintenance Costs: The annual savings are 84,000 English Pounds. (Material
savings of 60,000 English Pounds. Reduced disposal charges of 24,000 English Pounds.)
6.3 Payback Time: 3 months.
7.0 Cleaner Production Benefits
The system recovers 99% of the moulding material and sludge generation is reduced by 1,300 nrVyear.
Emissions are insignificant. Higher quality products are produced and the working environment is
improved.
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8.0 Obstacles, Problems and/or Known Constraints
None identified
9.0 Date Case Study Was Performed
Unknown
10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication.
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p6.
10.3 Level of Detail of the Source Material: Simple diagram of process provided.
10.4 Industry/Program Contact and Address: David Sumner, Project Engineer, Baxi Partnership,
Brownedge Road, Bamber Bridge, Preston PR5 6SN, England, telephone (0772) 36201.
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesfaurg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Dust, sand, clay, sludge
11.2 Process type/waste source: Iron foundry, scrubber sludge
11.3 Waste reduction technique: Recovery and reuse, sludge pump
11.4 Other keywords: United Kingdom, SIC 3322
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Dust, Sand, Clay, Sludge, Iron Foundry, Scrubber Sludge, Recovery and Reuse, Sludge Pump, United
Kingdom, SIC 3322
2-100
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***** DOCNO: 400-096-A-321*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Recovery and regeneration of pickling baths reduces wastewater generation
by 33 % and increases recovery rate of chlorides and ferric oxide.
Iron and Steel Basic Industries/ISIC 3710
Chlorhydric acid pickling baths are regenerated and recycled for pickling
of steel plates. The pickling baths go through a roasting oven where the
chlorhydric acid is recovered, along with ferric oxide powder which is sold.
Residual acid losses are neutralized and settled.
HC1 - 2 kg/ton steel, lime - 1 kg, wash water - 0.2 m3, energy (gas) -0.125
GJ.
Residual, used pickling baths, and washing water
Water
25,000,000 francs (1979 franc)
4.90 francs/ton of steel
Not reported
Capital investment is increased by 21,200,000 francs, but operating costs
are decreased by 5.06 francs/ton of steel. Recovered ferric oxide is sold
for 1.10 franc.
HC1 requirement reduced by 18 kg/ton steel, lime is reduced by 8.5 kg,
water by 0.2 m3.
Low waste techniques generates 0.2 m3 of wastewater containing 0.25
chloride ions, compared to 0.3 m3 water with 1.3 kg chloride ions with
conventional technology. Ferric oxide mud is reduced from 7 to 0.6 kg.
Wastewater generation is reduced by 33%, with a high recovery rate of
chlorides and ferric oxide. The technique could be extended to other
applications where chlorides are decomposed and recovery of metals is
profitable.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Pickling Steel Plates with Chlorhydric Acid,
After Hot Rolling: Recovery and Regeneration of Acid Pickling Baths",
Monograph ENV/WP.2/5/Add.96.
Steel, Pickling, Recovery, Recycling, Rinsewater, ISIC 3710
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*****DQCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
Headline: Use of acid purification unit on concentrated high temperature pickling liquor reduces iron
concentration
SIC Code: ISIC 2105, Pickling Steel
Name & Location of Company:
Metal Koting
Continuous Colour Coat Ltd.
1430 Martin Grove Road
Rexdale Ont. M9W 4Y1
Phone (416) 743-7980
4.0 Clean Technology Category
Technology Principle: This technology involves the use of an acid purification unit (APU) consisting of
filters and an ion exchanger to reduce iron content of the pickle acid.
5.0 Case Study Summary
5. 1 Process and Waste Information: In the original pickling process, no purification of the acidic liquor
was undertaken. The liquid was discarded in a continuous "bleeding" process after the "bleed" was
neutralized with lime.
The new process involves use of equipment consisting of three basic pieces and one optional piece:
an Eco-Tec Acid Purification Unit AP30-24 HT cartridge filter and ion exchanger, a feed pump,
an Eco-Tec sand filter and an optional 400 gallon (1 100 liter) water supply tank.
The pickle acid is pumped from the reservoir tank through a media filter to remove dirt and oil
particles. The acid then passes through a second filter (0.5 pm) to remove very fine paniculate and
filter media from reaching the resin bed in an ion exchange unit. The following stage contains three
steps per cycle: the water displacement stage, the byproduct (iron) removal stage, and the produce
(acid) return stage.
The water displacement phase allows the pickle acid into the resin bed, displacing the water from
the previous cycle. This water can be reused by sending it to the water supply tank, or sent to
drain. This stage lasts approximately one minute.
The byproduct stage allows the pickle acid to continue its flow through the resin bed trapping the
sulfate ions and allowing the iron to pass through to the drain. This phase also takes about one
minute.
The product return phase stops the flow of acid from the reservoir and starts a counterflow of water
from a pressurized source (main water line or water supply tank pump). The water picks up the
sulfate ions and returns them to the tank of sulfuric acid. This stage takes about two minutes.
This three phase cycle continues automatically until the dirt build-up in the media filter causes the
process to automatically shut down. A back flush procedure is necessary to clean the filter before
restarting the system again. Backflushing time is approximately one hour.
2-102
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Using the new process results in the reduction of the iron content of the acid solution from an initial
7.7% to a steady 2-3% during the latter half of the test period. An 89% decrease in use of sulfuric
acid and lime also resulted. No new materials are introduced in the process. Since pickling
uniformity is a product quality improvement, product quality is at least as good as before using the
APU, but this was not quantified.
5.2 Scale of Operation: Not reported
5.3 Stage of Development: The installation is fully implemented. Data are derived from the last month
of testing.
5.4 Level of Commercialization: The installation is commercially available. The vendor seems well
equipped and experienced in construction and maintenance of the equipment.
5.5 Material/Energy Balances and Substitutions:
Material Category
Quantity
Before
629,089
252
Quantity
After
67,558
28
Feedstock Use:
Sulfuric acid (Ibs/year)
Lime (tons/year)
(Computed)
6.0 Economics1''
6.1 Investment Costs: Investment costs were as follows:
Design and supply of equipment $84,000.00
Equipment installation $10,000.00
Start-up, supplies, etc. $ 2,500.00
Total $94,000.00
These costs do not include the test program nor the management personnel costs for the project.
6.2 Operational & Maintenance Costs: These costs are estimated at $2,500/year.
6.3 Payback Time: Payback time was calculated as 2.33 years. Annual savings on chemicals were
calculated as $43,937. Not included in the calculations are an estimated $8,000 saved annually on
sludge hauling.
7.0 Cleaner Production Benefits
Annual savings on chemicals were $25,942 for sulfuric acid and $17,995 for lime, or a total of $43,937.
An estimated $8,000 were saved on sludge hauling. The project demonstrated that sulfuric acid used in
preparing steel strip for electrogalvanizing could be reclaimed for continuous use.
8.0 Obstacles, Problems and/or Known Constraints
Except for some start-up problems, no other problems seem to have been encountered.
9.0 Date Case Study Was Performed: May 31, 1985 (date of source document)
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10.0 Contacts and Citation
10.1 Type of Source Material: Report
10.2 Citation:
Acid Purification Unit for Use on Concentrated High Temperature Pickling Liquor (Sulftiric Acid).
10.3 Level of Detail of the Source Material: More detailed cost information is available in the source
• document.
10.4 Industry/Program Contact and Address:
Mr. M. Schulz
Head Training Secion
Environment Canada
3439 River Road South
Ottawa, Ontario Kl OH3
Canada
Phone (613)991-1954
Fax (613)991-1635
10.5 Abstractor Name and Address: M. Stein, RIVM, Dept. LAE, Anthonie van Leeuwenhoeklaan 1,
Postbus 1, Bilthoven, Netherlands. Reformatted: Barbara M. Scharman, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Pickle liquor
11.2 Process type/waste source: Steel strip
11.3 Waste reduction technique: Acid purification, ion exchange, filtration, iron reduction, acid
reclamation
11.4 Other keywords: Canada
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Pickle Liquor, Steel Strip, Acid Purification, Ion Exchange, Filtration, Iron Reduction, Acid
Reclamation, Canada, ISIC 2105
2-104
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***** Doc # 501-016-A-OOO *****
1.0 Headline: High-carbon ferrochrome smelting process cuts electric power consumption in half.
2.0 SIC Code: SIC 3313
3.0 Name and Location of Company: Shunan Denko, Japan
4.0 Clean Technology Category:
This technology involves a process modification whereby an additional process step is added prior to the
ore entering the furnace.
5.0 Case Study Summary
5.1 Process and Waste Information: This plant makes high-carbon ferrochrome suitable as an addition
agent in the production of stainless steel. Pellets of ore mixed with carbon are hot-charged into a
closed-type electric furnace. The main feature of this technique is a pre-reduction step ahead of the
furnace. Chrome ore is palletized along with coke, binder and flux, and roasted in a rotary kiln.
By pelletizing the fine, low-grade chrome ore more commonly available around the world, it is
possible to use the closed-type electric furnace. This enables a substantial reduction in unit power
consumption, and in pollution-abatement costs otherwise spent to control fugitive dust from handling
dusty ore in the open.
5.2 Scale of Operation: A 60,000-ton/year plant uses this operation.
5.3 Stage of Development: The technology is fully implemented.
5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions: Energy use after the process modification is 2,000 to
2,100 kWh/ton of ferrochrome.
6.0 Economics
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Compared to the traditional smelting process this process cuts energy consumption by 50 % and reduces dust
generation by eliminating one of the ore handling steps.
8.0 Obstacles, Problems and/or Known Constraints
None were identified.
9.0 Date Case Study Was Performed
1974
2-105
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10.0 Contacts and Citation
10.1 Type of Source Material: Book
10.2 Citation: Process Technology and Flowsheets, articles which appeared in Chemical Engineering
over the last five years. V. Cavaseno and Staff of Chemical Engineering eds., McGraw-Hill, NY,
NY, 1979. High-Carbon Ferrochrome Route Slashes Power Use, Kazuo Ichikawa. Pg. 110.
10.3 Level of Detail of the Source Material: Additional detail of each of the steps and ingredients as
well as a process flowsheet are included in the article.
10.4 Industry/Program Contact and Address: Kazuo Ichikawa, Deputy Manager, Administration and
planning Dept., Metals and Alloys Div. Showa Denko, K.K.
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Ore dust
11.2 Process type/waste source: Blast furnace, ferrochrome smelting
11.3 Waste reduction technique: Pelletized ore, closed-type electric furnace
11.4 Other keywords: Japan, energy conservation
KEYWORDS: Ore Dust, Blast Furnace, Ferrochrome Smelting, Pelletized Ore, Closed-Type Electric Furnace,
Japan, Energy Conservation, SIC 3313
2-106
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LEATHER TANNING AhfDFfNiSHlNG
-------
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***** DOCNO: DOCUMENT NOT AVAILABLE (404) *****
1.0 Headline: Methane gas produced from tannery waste biomethanisation is usable for feeding boilers.
2.0 ISICCode: Not provided
3.0 Name and Location of Company:
AloyM
CTC
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:+33 78695012
Tlx:340497 F
Fax:+33 78612857
4.0 Clean Technology Category
Technology Principle: Solid waste benefits - nitrogen; Energy saving; Other environmental claims/cost of
dumping saving. 75% less COD in waste. 62% less volatile and 44% less volume. 515 litres of gas (73%
methane) per kg of volatile material, available for tannery boilers.
Used in: Waste treatment Energy usage.
Cleanness: Good - best available to-date. The organic matter transformation gives a lower quantity of waste
for disposal. The waste is more friendly with the environment and gas is recovered.
5.0 Case Study Summary
Stage of Development: Trial / Prototype stage 1-10 estimated number of enterprises in year 2000. l-5m sq
ft of leather produced to date. Available: World First developed in: 1985
Results of Application: A mixture of liquid sludge and ground fleshings is sent to a digester with a 20 days
retention time. Temperature is maintained at 35 deg C. Gas production is 615 litre of gas with 73 % methane
per kg of volatile matter sent to the digester. Gas, after washing and sulphide removal, is usable for feeding
boilers in tanneries.
6.0 Economics
Investment Costs: Implementation costs: #1000001 + '
Payback Time: 4.5 years
7.0 Cleaner Production Benefits
Wastes: The elimination levels are: 75% COD; 44% dry material; 62% volatile material. Volume of waste
to be disposed of can be reduced by 40%. 515 litres of gas (73% methane) per kg of volatile material,
available for tannery boilers.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: High costs in investment. Technical problems of grease during cold periods.
2-107
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9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Aloy M
CTC
France
Regulatory Compliance: Financial support from EEC (Project BM/185/83) and AFME (French Energy
Agency).
Citation:
1. Biomethanisation des residus de tannerie: une experience industrielle, Aloy M, Mermet R &
Sanejouand J, Industrie du Cuir, 1987, (5), 23-27.
2. Biomethanisation of tannery wastes : an industrial experiment, Aloy M, Mermet R & Sanejouand J,
JALCA, 1989, 84, (4), 97-109.
Keywords: Leather, Tanning, Biomethanisation, Process Alternatives, Methane, Energy Reclamation
2-108
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***** DOCNO: DOCUMENT NOT AVAILABLE (407) ****
1.0 Headline: Elimination of leather waste by production of ceramic pastes for paving and brickwork.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Barcelo ACO
INESCOP
PO Box 253
Poligono Industrial 'Campo Alto'
03600 Elda
Alicante
Spain
Tel:5395213
Tlx:68269
Fax:5381045
4.0 Clean Technology Category
Technology Principle: Recycled chromium; Solid waste benefits - chromium; Reduction in volume in the
solid wastes. The production of a combustible carbon matrix. The production of activated carbons for use in
adsorption. The production of combustible chemical products through distillation. Concentration of chromium
oxide for storage and subsequent recovery.
Used in: Waste treatment.
Cleanness: Reasonable - better than other processes. It is a controlled process for the elimination of the
leather wastes. It transforms the chromium compounds incorporated into the leather during tanning in
chromium oxide (HI) of great chemical stability. It avoids risks of contamination.
5.0 Case Study Summary
Stage of Development: Trial / Protype
Results of Application: Two ways to eliminate waste from the tanning and footwear industries.
1) Addition of small percentages (1-2%) of shredded leather to ceramic pastes for paving and exterior
brickwork. This produced the occurrence of porosity due to the combustion of organic matter, and this
process is therefore recommended only when special textures in the materials are required.
2) Under controlled temperature and atmospheric conditions in the inside of the suitable ovens, a
carbonised material having acceptable calorific capacity, combustible chemical compounds through
distillation, recovery of chromium oxide and production of activated carbons could be obtained from
the leather wastes, for industrial purposes such as adsorbents.
6.0 Economics: Not reported
7.0 Cleaner Production Benefits
Reduction in volume of the solid wastes.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
2-109
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7.0 Cleaner Production Benefits
Wastes- Total replacement of chrome by Synektan TAL would satisfy any requirement regarding solid or
liquid chrome-bearing waste. If a practical chrome offer, eg 1% Cr2O3, is retained (to maintain leather
character), chrome discharges in the effluent might be approximately 10 PPm in the mixed wastestream. By
optimising conditions, that level can be significantly reduced.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: No undesirable effects on the environment at present - legislation may apply Consent
Limits. Post tanning steps have to be modified to take account of A1 + Ti in the leather.
9.0 Date Case Study was Performed: Not reported
• 10.0 Contacts and Citations
Abstractor and Address: Dr. AD Covington, British Leather Confederation
Regulatory Compliance: EC supported Demonstration Project (ACE/88/UK/002/A21) currently being
conducted at The British Leather Co Ltd, in collaboration with the British Leather Confederation.
Industry/Program Contact and Address: Ian Tate, ICI Colours and Fine Chemicals
Citation:
1. Tannages based on aluminium III and titanium III complexes by Covington, AD., J Amer Leather Chem
Assoc, 1987 82(1)1.
2. Leather tanning process using aluminium III and titanium IV complexes by Covington, AD.
3. Proceedings IULTCS Conference, Philadelphia, USA by Tate IP, 1989.
Product code 36003
Company Information Pack
Keywords: Leather Tanning, Chromium Compounds, Chemical Alternatives, Source Reduction, Aluminum,
Titanium
2-112
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***** DOCNO: DOCUMENT NOT AVAILABLE (386) *****
1.0 Headline: Deliming using carbon dioxide in place of ammonium compounds and organic acids reduces odours
and creates better working conditions.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Petersson M
AGAAB
S-181 81 Lidingo
Sweden
Tel:+46 8 7311000
Tlx: 19820
Fax:+46 8 7652487
4:0 Clean Technology Category
Technology Principle: Alternative to ammonia; Liquid waste benefits - Bod/Cod Odour reduction; Better
working conditions. (Cf 5) No ammonia odour. No lifting of sacks. Automation possible.
Used in: Beamhouse.
Cleanness: Very good - best possible. Ammonium-free process which does NOT increase COD (cf organic
acids, etc).
5.0 Case Study Summary
Stage of Development: Limited commercial use 101-500 estimated number of enterprises in year 2000. 5m
sq ft+ of leather produced to date.
Level of Commercialization: 2.5 years in commercial use. Available: Europe, N. America, S. America.
First developed in: 1987
Results of Application: The process replaces ammonium compounds and organic acids with carbon dioxide
as the deliming agent.
6.0 Economics
Investment Costs: #5001-10000
Payback Time: 1-2 years
7.0 Cleaner Production Benefits
Wastes: No ammonium / nitrogen load from the deliming step.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: HjS formation has to be controlled. Time consumption for thick hides.
9.0 Date Case Study was Performed: Unknown
2-113
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10.0 Contacts and Citations
Abstractor and Address:
Walter R
AGAAB
S-181 81 Lidingo
Sweden
Tel:+46 8 7311000
Tlx: 19820
Fax:+46 8 7652487
Industry/Program Contact and Address:
MunzKH
Vesuchsanstalt fiir Lederindustrie .
Citation:
1. IULTCS 20th Congress, Philadelphia, USA October 15-19, 1989.
2. Leder December 1989, p 251.
3. Leder June 1990, p 103.
4. Ind Cuir, January 1990, p 30.
Keywords: Leather, Tanning, Deliming, BOD/COD Reduction, Chemical Alternatives, Carbon Dioxide
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***** DOCNO: DOCUMENT NOT AVAILABLE (387) *****
1.0 Headline: Tanning using vegetable tannins and aluminium sulphate in the same bath allows total replacement
of chrome.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company: Not reported
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Liquid waste benefit - chromium; Solid waste benefits -
chromium; Energy saving; Other environmental claims - chrome-free solid waste. 100% replacement of
chrome.
Used in: Tanning.
Cleanness: Reasonable - better than other processes. Comparing with full vegetable tanning organic load in
effluent is less. Discharges of aluminium may be subject to environmental pressure in the future.
5.0 Case Study Summary
Stage of Development: Trial / Protype stage
Level of Commercialization: First developed in: 1988
Results of Application: Total replacement of chrome with a combination of aluminium sulphate and vegetable
tannins for the manufacturing of upper leather and clothing leather. The above tanning agents are added in
the same bath. There is no formation of precipitation.
6.6 Economics: Not reported
7.0 Cleaner Production Benefits
Wastes: Total removal of chrome from the effluent. Reduction of vegetable tannins in effluent compared
with effluent from vegetable tanned upper leather.
Feedstocks: Chrome-free solid waste. 100% replacement of chrome.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Discharges of organic material.
9.0 Date Case Study was Performed: Unknown
10.0 Contacts and Citations
Abstractor and Address:
Pateropoulou Despina
Hellenic Leather Centre SA
Thisseos7A
176 76 Kallithea
Athens, Greece
Tel:(01)9025595/6/7
Fax:(01)9025598
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Citation:
1. Boziaris E, Tonigold L & Heidemann E: Eine unerwartete Beobachfung bei der Gerbung mit
pflanzengerbstoffen Leder 39 (1988) 236-238.
2. Prof Dr E Heidemann. Institut fur Biochemie, Abtly. Eiweiss und Leder, Technische Hochschule
Darmstadt.
Keywords: Leather, Tanning, Vegetable Tanning, Aluminum Sulphate, Chemical Alternatives
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1.0 Headline: Use of fresh hides and skins without preservatives or biocides by a beamhouse reduces water,
energy, and time demands.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
4.0 Clean Technology Category
Technology Principle: Alternative to chloride; Liquid waste benefit - chloride; Solid waste benefits -
chloride; Liquid waste benefits - total solids; Energy saving - 100% less salt in effluent coming from soaking
60% less water-demands for soaking 60% less required time for soaking.
Used in: Beamhouse. - , - ,- -j
Cleanness: Reasonable - better than other processes. Given that the removal of salt from liquid waste is
nearly impossible, the above process is really important when the receiver is not the sea, as it happens usually
in Greece. This method is not really a new technology. Some tanneries, simply, exploit the fact that these
are located near slaughterhouses.
5.0 Case Study Summary
Stage of Development: -1m sq ft of leather produced to date. Available: World
Results of Application: Raw hides and skins, without any preservatives or biocides, are used in beamhouse.
This rawstock needs less amount of water, and less time for soaking.
6.0 Economics: Not reported
7.0 Cleaner Production Benefits
Wastes: Total removal of salt from liquid and solid wastes coming from soaking.
Energy Use: Energy saving - 100% less salt in effluent coming from soaking 60% less water-demands for
soaking 60% less required time for soaking
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Technical problems.
9.0 Date Case Study was Performed: Unknown
10. Contacts and Citations
Abstractor and Address:
Pateropoulou Despina
EL.KE.DE. S.A.
Thisseos 7A
Kallithea 176 76
Athens
Greece
Tel:01-9025595/6/7
Fax:(01)9025598
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Notes: Information is coming from tanneries which use, from time to time, Fresh raw material.
Keywords: Leather, Tanning, Chloride (Salt), Salt Removal, Source Reduction
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1.0 Headline: Recycling of chromium as tanning agent from the effluents of the tanning process through
precipitation of chromium by adding magnesium oxide.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Van VHet M
TNO, Leather & Shoe Research Institute
PO Box 135
5140 AC Waalwijk
Mr van Coothstraat 55
5141 ER Waalwijk
The Netherlands
Tel:0031-4160-33255
Fax:0031-4160-41735
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Recycled chromium; Better uptake of chromium -
Chromium free waste-liquors. 99.9% reduction of chromium in waste Cr-liquors.
Used in: Waste treatment.
Cleanness: Very good - best possible. Almost total removal of chromium from the tanning effluents.
Discharges of magnesium may be subject to environmental pressure in the future.
5.0 Case Study Summary
Stage of Development: Available: Europe
Results of Application: This technology combines the complete removal of chromium from the factory's
effluents, with economic benefits which will be based on the reusual of the recovered chromium.
6.0 Economics
Payback Time: 2.5 to 3 years
7.0 Cleaner Production Benefits
Wastes: The chromium content of the effluents from the tanning process was reduced from 4000 ppm to 2
ppm, which means 99.9% reduction.
Feedstocks: Chromium free waste-liquors. 99.9% reduction of chromium in waste Cr-liquors.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Magnesium in effluents.
9.0 Date Case Study was Performed: Unknown
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10.0 Contacts and Citations
Abstractor and Address:
Barla M
Hellenic Leather Centre SA
Thisseds 7A
176 76 Kallithea
Greece
TeI:(01)9025595-6-7
Fax:(01)9025598
Industry/Program Contact and Address:
Hellenic Leather Centre SA, Thisseos 7A, 176 76 Kalli
John Germanakos Gennanakos SA
Tannery 5 Leof Irinis
Agia Anna
Rentis
GR 182 33
Athens
Greece
Tel:(01)3461550
Keywords: Leather, Tanning, Chromium Recycling, Precipitation, Magnesium Oxide
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1.0 Headline: Fatliquoring using glue stock fat reduces waste generation and commercial fatliquor costs.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
4.0 Clean Technology Category
Technology Principle: Liquid waste benefits - grease; Solid waste benefits - grease. All fat from fleshings
can be re-used. Less fatliquors have to be bought from chemical companies.
Used in: Dyeing & Fatliquoring.
Cleanness: Good - best available to-date.
5.0 Case Study Summary
Stage of Development: Research & Development (Experimental stage) 11 -50 estimated number of enterprises
in year 2000. Available: World
Results of Application: A process for the utilization of gluestock fat. The fat is transesterifized together with
rapeseed oil using an immobilized lipese as catalyst. This transesterification lowers the melting point of the
fat which makes it more suitable for fatliquoring of leather. It has been shown possible to replace up to 80%
of a commercial fatliquor with this fat without any negative effect on the leather. The reaction time for the
transesterification is between 4-8 hours.
6.0 Economics
Investment Costs: #1-5000
7.0 Cleaner Production Benefits
Wastes: The fat fraction from the fleshings can be reused for the fatliquoring.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: High costs
9.0 Date Case Study was Performed: Unknown
10.0 Contacts and Citations
Abstractor and Address:
Rydin S
Danish Technological Institute
Denmark
Industry/Program Contact and Address:
Rydin S
Danish Technological Institute
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Citation:
1. Fatliquoring of leather using enzyme treated gluestock fat by Rydin S. Internal Report 1988.
2. Biological conversion of low grade fats by Rydin S. Licentiate Thesis, 1989.
Datasheet exists on product - but not for this application.
Keywords: Leather, Tanning, Fat Liquoring, Gluestock Fat Transesterification, Fat Recycling
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1.0 Headline: Incineration of chrome shavings allows extraction and reuse of chromium from ash.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
4.0 Clean Technology Category
Technology Principle: Recycled chromium
Used in: Waste treatment
Cleanness: Very good - best possible
5.0 Case Study Summary
Stage of Development: Trial / Protype stage. Available: World
Results of Application: The technique allows the combustion of chrome shavings to take place without any
emission of chromium and ensures that the chromium in the ash will keep the original trivalent form and not
be oxidized to hexavaient chromium. The chromium can then be extracted from the ash, 40% of which is
chromium '(Cr2O3). The incineration takes place under low oxygen - low temperature conditions.
6.0 Economics
Investment Costs: Implementation costs: #1000001 +
7.0 Cleaner Production Benefits
Wastes: The chrome shavings can be re-used.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: High costs. Sensitive to changes in raw material. Needs large amount of chrome
shavings.
9.0 Date Case Study was Performed: Unknown
10.0 Contacts and Citations
Abstractor and Address:
Rydin S
Danish Technological Institute
Denmark
Industry/Program Contact and Address:
Frendrup W
Danish Technological Institute
Citation: 1. Combustion of chrome shavings, Danish Technological Institute, Report 1987
Keywords: Leather, Tanning, Chromium Recycling, Incineration
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1.0 Headline: Chilling hides at slaughterhouses using ice reduces use and wasting of salt preservative.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Schroeder P
Hude-Centralen
Sindalsvej 8
DK-8240 Risskov
Denmark
Tel:+45 86212100
Tk:68150
4.0 Clean Technology Category
Technology Principle: Less salt in effluent.
Used in: Rawstock
Cleanness: Reasonable - better than other processes
Technical problems in uniform chilling of the hides. If the temperature rises in any process stage because of
technical problems the quality will be lower.
5.0 Case Study Summary
Stage of Development: Limited commercial use
Level of Commercialization: 2-3 years in commercial use. Available: World
Results of Application: The hides are iced directly at slaughterhouses immediately after slaughter (using 5
kg ice per hide). The ice is produced by installed ice making machines. After icing, the bides are sent
overnight to Hude-centralens warehouse for grading and salting. The warehouse is refrigerated to 8 deg C
in order to minimise bacterial action and preserve quality. According to Hude-centralen the shelf life of chilled
unsalted hides is two weeks.
6.0 Economics
Investment Costs: Implementation costs: #1-5000
7.0 Cleaner Production Benefits
Wastes: No salt used for short-term conservation. However, at Hude-centralen most of the hides are salted
before transportation to tanneries.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Technical problems in uniform chilling of the hides. If the temperature rises in any
process stage because of technical problems the quality will be lower.
9.0 Date Case Study was Performed: Unknown
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10.0 Contacts and Citations
Abstractor and Address:
Rydin S Danish Technological Institute
Denmark
Industry/Program Contact and Address:
Rydin S, Danish Technological Institute
Citation:
1. Iced hides are better, Schroeder P, Leather, 1990, 192, 34-37.
2. Technical literature, Hude-centraien, Denmark.
Keywords: Leather, Tanning, Hide Preservation, Process Alternatives, Ice Chilling, Salt Use Reduction
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1.0 Headline: Deliming using sodium bicarbonate and hydrochloric acid reduces inorganic ammonia effluent
loadings.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Heidemann E.
Technische Hochschule Darmstadt/Department of Protein and
Leather
Petersenstrasse 22
D-6100 Darmstadt
West Germany • .
Tel:0615/16 2175
4.0 Clean Technology Category
Technology Principle: Alternative to ammonia; Liquid waste benefit - ammonia; Liquid waste benefits -
BOD/COD; Other environmental claims/deliming with CO2. Ammonia might be reduced by 75%.
Used in: Beamhouse
Cleanness: Not so good
The cleanness of the process is good but there is a loading of sodium chloride or sodium sulphate in the
effluent.
5.0 Case Study Summary
Stage of Development: Trial / Protype stage. Available: World. First developed in: 1987
Results of Application: Rapid and safe deliming process with hydrochloric acid (and other strong acids) in
the presence of sodium hydrogen carbonate avoiding a pH value below 6 and without using ammonium salts.
6.0 Economics
Investment Costs: Implementation costs: #5001-10000
7.0 Cleaner Production Benefits
Wastes: Replacement of ammonia salts by sodium hydrogencarbonate and hydrochloric acid in the deliming
process would reduce the effluent loading of inorganic ammonia. The reduction would be 75 % ammonia. This
would not satisfy the requirements. In this case the bating products must not contain ammonia salts and also
no ammonia products may be used in the other processes.
8.0 Obstacles, Problems and/or Known Contraints
Problems Encountered: Undesirable effects on the environment from formation of sodium chloride or sodium
sulphate. Technical problems in that an automatic adding system for the acid is required.
9.0 Date Case Study was Performed: Unknown
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10.0 Contacts and Citations
Abstractor and Address:
Pauckner W
Westdeutsche Gerberschule Reutlingen
PO Box 29 44
Erwin-Seiz-Strasse 9
D-7410 Reutlingen, West Germany
Industry/Program Contact and Address:
Heideman E
Technische Hochschule Darmstadt
Dept Protein & Leather
Petersenstrasse 22
D-6100 Darmstadt
West Germany
Citation:
1. Hein A, Herrera P and Heidemann E, Leder, 1988, 39, (8), 141-145.
Keywords: Leather, Tanning, Deliming, Ammonia, Sodium Hydrogencarbonate
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1.0 Headline: Dyeing of leather with liquid 1:2 metal complex dyestuffs (Levaderm dyes) reduces BOD, COD,
and salt content in effluent.
2.0 ISICCode: Not provided
3.0 Name and Location of Company:
Traubel H
Bayer AG
ATEA-Leder
Bayerwerk
D-5090 Leverkusen
West Germany
Tel:0214 3071180
Tlx:85103-257
4.0 Clean Technology Category
Technology Principle: Liquid waste benefits - BOD/COD; It is possible to use these dyestuffs in drum,
spraying and roller coating. They can be used in water and organic solvents (alcohol). They have no salts as
do powder dyes and give good properties. •
Used in: Dyeing & Fatliquoring
Cleanness: Reasonable - better than other processes
By using these dyestuffs, the exhaustion of the float is good. By spraying or roller coating, there are no
, effluents. The COD is similar.
5.0 Case Study Summary
Stage of Development: Widespread use 501 + estimated number of enterprises in year 2000. 5m sq ft+ of
leather produced to date.
Level of Commercialization: 8-10 years in commercial use. Available: World
Results of Application: A new universally applicable range of liquid dyestuffs is described. The liquid
dyestuffs are distinguished by good solubility in alcohols and water and by their strong bond to the leather
fibers. They have only a very slight tendency to migrate by heat, solvents, water or perspiration. Good
lightfastness owing to their metal complex character and high build up in the drum dyeing of different kinds
of leather round off the advantage of the range.
6.0 Economics: Not reported
7.0 Cleaner Technology Benefits
By using 1:2 metal complex dyestuffs in the drum: The linking to the fiber is better, resulting in a reduction
of COD in the effluent of the dyeing process. In addition, the salt content of the effluent is reduced owing
to the liquid formation of the dyes.
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8.0 Obstacles, Problems and/or Known Contraints
Problems Encountered: Undesirable effects on the environment due to addition of a small quantity of metals
to the effluent. Several azo dyes (with carcinogenic amino components) are subject of discussions concerning
the health risks.
9.0 Date Case Study was Performed: Unknown
10.0 Contacts and Citations
Abstractor and Address:
Pauckner W
Westdeutsche Gerberschule Reutlingen
PO 29 44, Erwin-Seiz-Str 9
D-7410 Reutlingen
West Germany
Tel: 07121/40056
Tlx: 729 868
Fax: 07121/4 54 93
Industry/Program Contact and Address:
Traubel H
Bayer AG
ATEA Leder
Bayerwerk
D-5090 Leverkusen
Tel: 0214/3071180
Tlx: 85103-257
Citation:
1. Westphal J, Proceedings VGCT Conference, Maastrickt, 1983.
2. Universal use of liquid metal complex dyestuffs, Westphal J, Leder, 1983, 34, 148-151/Leder Haute
Markt, 1983, 29, 8-10.
3. Newer practical experiences with liquid dyestuffs in drum dyeing, Muller W and Westphal J, Leder
Haute Markt, 1985, 37, 38-40 /Bayer Information for the Leather Industry, 1985.
Company information pack.
Keywords: Leather, Tanning, Leather Dyes, Metal Complex Dyestuffs, BOD/COD Reduction
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1.0 Headline: Partial replacement of chrome by an aluminium complex tanning agent may reduce chrome in spent
tanning liquor by -90 percent.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
EL.KE.DE. S.A.
Thisseos 7A, Kallithea
176 76 Athems
Greece
Tel:(01) 9023395/6/7
Fax:(01) 9023398
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Less chloride required; Better uptake of chromium; Solid
waste benefits - chromium; Other environmental claims -Chrome-free solid by-product by pretanning for wet
white. In pilot plant trials chrome in the spent tan liquor was reduced by approx 90%.
Used in: Tanning.
Cleanness: Good - best available to-date. Pretanning with aluminium complex salts not only simplifies the
tanning process but reduces drastically pollution problems resulting from its combination-tanning with reduced
quantities of chrome-salts. Only problem remains the future environmental pressure on aluminium discharges.
5.0 Case Study Summary
Stage of Development: Research & Development stage 1 1-50 estimated number of enterprises in year 2000.
Results of Application: (1) Pretanning for wet white, to reduce chrome presence both in the effluent and in
the solid waste. Interesting applications of the wet white solid waste after the removal of aluminium tanning
agent. (2) Partical replacement of chrome in main tannage to reduce chrome offers and aiding chrome uptake.
Without changing the chrome character of the leather nevertheless improving its physicomechanical properties.
6.0 Economics: Not reported
7.0 Cleaner Production Benefits
Wastes: In pilot plant trials chrome in the spent tan liquor was reduced by approximately 90%.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Undesirable effects - Legislation may apply consent limits. Post-tanning operations
have to take into account the hardness of leather resulting from an aluminium pretanning. Corrections in
fatliquoring and retannage must be modified.
9.0 Date Case Study was Performed: Unknown
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10.0 Contacts and Citations
Citation:
Nikolaos Mamelakis
EL.KE.DE. S.A.
Thisseos 7a
176 76 Kallithea
Athens
Greece
Keywords: Leather, Tanning, Chemical Alternatives, Chromium, Aluminum Complex
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1.0 Headline: Use of titanium salt as a pretanning agent improves chrome uptake, reduces chromium in effluent,
and produces chrome-free shavings.
2.0 ISICCode: Not provided
3.0 Name and Location of Company:
Bagni W
Bitossi Dianella SpA
Via Pietramarina 18
1-50053 Sovigliane
Vinci
Firence
Italy
Fax:+57150 98 87
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Less chloride required; Better uptake of chromium; Liquid
waste benefit - chromium; Solid waste benefits - chromium; Other environmental claims/chrome-free solid
by-products by pretanning for wet white. No chrome in solid wastes. Chrome can be reduced in the retanning.
Used in: Tanning
Cleanness: Good - best available to-date
Pretannage with titanium salts reduces the discharge of chrome in the effluent. The resulting chrome-free
shavings are more suitable for versatile utilisations.
5.0 Case Study Summary
Stage of Development: Limited commercial use
Level of Commercialization: 2 years in commercial use. Available: Europe. First developed in: 1986
Results of Application: Non-chrome tanning agent useful in pretannage. All kinds of leathers were made by
using 4-10% of ammonium titanyl sulphate. The received wet white can be stored for a long time without
biocides. The solid wastes, eg, shavings, cuts, can be used for the production of animal feed, fertiliser and
gelatine. The wet white can be retanned with chrome, vegetable and synthetic tanning agents for clothing
leather, shoe upper leather, leather for leather goods and sole leather.
6.0 Economics: Not reported
7.0 Cleaner Production Benefits
Wastes: Total replacement of chrome is given in the pretanning effluents and the quantity of chrome in the
retanning process can be reduced. The uptake of chrome is also better.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Undesirable effects on the environment from ammonia in the effluent. Very low pH
required at the beginning of the pretannage.
9.0 Date Case Study was Performed: Unknown
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10.0 Contacts and Citations
Abstractor and Address:
Gennann H-P
Westdeutsche Gerberschule Reutlingen
PO 29 44, Erwin-Seiz-Str 9
D-7410 Reutlingen
West Germany
Tel: 07121/40056
Tlx: 729 868 Fax: 07121/454 93
Citation:
1. Pauckner W, Proceedings 20th IULTCS Congress, Philadelphia, 1989.
Company information pack.
Keywords: Leather, Tanning, Chromium, Chemical Alternatives, Titanium Salt, Ammonium Titanyl Sulphate
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1.0 Headline: Pretannage of hides using aluminium sulphate for the production of wet white saves energy and
reduces chrome in spent tan liquor by as much as 90-95 %.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Heidemann E
TU Darmstadt / Dept Protein & Leather
Petersenstrabe 22
D-6100 Darmstadt
Tel:06151/16 2175
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Less chloride required; Better uptake of chromium; Liquid
waste benefit - chromium; Solid waste benefits - chromium; Energy saving; Chrome free solid by-products
by pretanning for wet white. Chrome in spent tan liquor might be reduced by 90-95 %.
Used in: Tanning
Cleanness: Good - best available to-date
The pretannage with aluminium salt can make real reductions of discharged chrome with no current additional
environmental problems. Discharges of aluminium may be subject to environmental pressure in the future.
5.0 Case Study Summary
Stage of Development: Limited commercial use 11 -50 estimated number of enterprises in year 2000. I m sq
ft of leather produced to date
Level of Commercialization: 4 years in commercial use. Available: World. First developed: 1984
Results of Application: Aluminium sulphate alone or aluminium salts in combination with a polymer tanning
agent are used for the preservation of pelts to yield wet white. The wet white is stable to shaving and ils
retanning with chrome salts results in a leather, that is stable to boiling. Using aluminium sulphate alone
8-10%, in combination with the polymer 1-2% of the aluminium salt are required respectively. In the first
case it is necessary to wash out the aluminium salt with a pickle solution before the retannage with chrome
or other tanning agents. In the second case the obtained wet white may be retanned immediately.
6.0 Economics
Investment Costs: Implementation costs: #5001-10000
Payback Time: 5 years
7.0 Cleaner Production Benefits
Wastes: The quantity of chrome for the retannage is smaller and a better uptake of the chrome salt is
achieved. The effluent loading of chrome is reduced as compared to a normal chrome tanning and the wet
white shavings are chrome-free. Chrome in spent tan liquor might be reduced by 90-95%.
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8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Undesirable effects on the environment - aluminium in effluent. It is not possible
to get the same softness of the leather as with a chrome tannage. The wet white cannot be stored for a long
time because of mold.
9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Pauckner W
Westdeutsche Gerberschule Reutlingen
Post Box 29 44
Erwin-Seiz-Str 9
D-7410 Reutlingen
Tel:07121/4 00 56
Tlx:729 868
Fax:07121/45493
Industry/Program Contact and Address:
Heidemann E
TU Darmstadt/Dept Protein & Leather
Petersenstrasse 22
D-6100 Darmstadt
West Germany
Tel: 06151/16 2175
Citation:
1. Compensation of chrome by other tanning agents by Zissel A et al Leder 1980 31(2)17-24
2. Tanning with aluminia salts by Bay B et al LMH 1985(14)28
3. Production of wet white by Heidemann E et al Leder 1982 v.33 p. 131-136, 1985 v.36 p!70-175, 1986
v.37 p.221-224, 1987 v.38 p.71-75
4. Heidemann E & Balstros B Leder 1984 v.35 p. 186-189 Lutan V (BASF), Tl/P 3042 d
Company information pack
Keywords: Leather, Tanning, Pretannage, Aluminum Sulphate, Chromium Alternatives, Wet White
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1.0 Headline: Unhairing with enzymes and chrome tanning using the injection method (penetrator) saves
chemicals and water and reduces effluent COD loads.
2.0 ISICCode: Not provided
3.0 Name and Location of Company:
Petersen A
J Krause GmbH
Post Box 50 09 68
Planckstrabe 13-15
D-2000
Hamburg 50
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Less chloride required; Recycled chromium; Better uptake
of chromium; Liquid waste benefit - chromium; Liquid waste benefits - BOD/COD; Better working
conditions. Less COD in effluent, saving of chrome-discharge from residual tanning liquors, saving chemicals
and water.
Used in: Beamhouse Tanning
Cleanness: Good - best available to-date
5.0 Case Study Summary
Stage of Development: Trial / Protype & Limited commercial use 11-50 estimated number of enterprises in
year 2000.
Level of Commercialization: 1 year in commercial use. Available: Europe, N. America, Australia & NZ
& Asia. First developed in: 1980.
Results of Application: The new process technology uses pressure to inject the chemicals from the flesh- or
grain-side into the hides and skins. Basing on a direct recycling of the process liquors, the new method saves
chemicals and water and reduces the effluent loading. The technology reduces the problem of diffusion
drastically, thereby accelerating the desired process and achieving a more homogenous distribution of the
chemicals inside the hides. The hides remain in the orientated position throughout the whole process,
improving the possibilities of rationalization of through-feed processing.
6.0 Economics
Investment Costs: Implementation costs: #1000001 +
7.0 Cleaner Production Benefits
Wastes: COD is reduced by unhairing with enzymes and saving the hair and wool of hides and skins. The
direct and continuous recirculation of the chrome liquor in the penetrator system eliminates an effluent loading
in the tanning process.
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8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: High costs initial outlay for the machine.
9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and. Address:
Germann HP
Westdeutsche Gerberschule Reutlingen
Post Box 29 44
Erwin-Seiz-Str 9
D-7410
Reutlingen
Tel:07121/4 00 56-58 Tlx:729 868
Fax:07121/45493
Industry/Program Contact and Address:
Petersen A
See above
Citation:
1. Unhairing and tannage with the penetrator by Petersen A & Germann HP Leder 1989 40 (9) 187-191.
2. Pauckner W. Proceedings JULICS Conference Venice 1983.
3. Pauckner W. Proceedings B Lederkongress Budapest 1986.
4. Pauckner W. Proceedings Symposia Freiburg 1989.
Information pack of the machine factory
Keywords: Leather, Tanning, Chromium Recycling, Source Reduction, Chemical Injection, Unhairing, Alternative
Process, BOD/COD
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1.0 Headline: Recycling of lime sulphide effluent using ultrafiltration reduces wastes and odor.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Aloy M
CTC (Centre Technique Cuir Chaussure Maroquinerie)
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:(33)78 69 50 12
Tlx:340 497 F -
Fax:(33)78 61 28 57
4.0 Clean Technology Category
Technology Principle: Liquid waste benefit - ammonia; Recycled sulphide; Liquid waste benefits -
BOD/COD; Liquid waste benefits - suspended solids; Odor reduction 90 % residual sulphide recycled. 50-60 %
ammonia recovered as solid waste.
Used in: Beamhouse
Cleanness: Good - best available to-date
Using ultrafiltration can make very good sulphide recovery without damaging of hides and skins and giving
the possibility to recover some proteins.
5.0 Case Study Summary
Stage of Development: Limited commercial use 11-50 estimated number of enterprises in year 2000. 5m sq
ft+' of leather produced to date
Level of Commercialization: 10 years in commercial use. Available: World. First developed in: 1980
Results of Application: Recycling of lime sulphide effluent after ultrafiltration treatment giving two parts:
1. An ultrafiltrate (90% of the volume) containing sulphide, a little lime and a low quantity of organics.
2. A concentrate (10% of the volume) with the insoluble lime, and large quantities of organics (proteins).
The ultrafiltrate can be reused for a new lime sulphide process.
6.0 Economics
Investment Costs: Implementation costs #50001-100000
Payback Time: 18 months
7.0 Cleaner Production Benefits
Wastes: COD elimination in concentrate 50 to 60%. Total nitrogen 50 to 60%. Sulphide 90% in ultrafiltrate.
Odor
2-138
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8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: High costs and clogging of membranes with calcium hydroxide
9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Aloy M
CTC (Centre Technique Cuir Chaussure Maroquin
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:(33)78 69 50 12
Tlx:340497
Fax:(33)7861 2857
Industry/Program Contact and Address:
Aloy M
CTC (Centre Technique Cuir Chaussure Maroqui
Donikian Mr
Gordon Choisy (reptile tannery)
5 rue de la Grande-Haie
77130 Montereau
France
. Tel:(33)l 64 32 13 50
Tlx:211 362
Fax:(33)l 47 00 70 48
Gand Mr
Tacham (reptile tannery)
25 rue Louis Chatin
42400 Saint Chamond
France
Tel:(33)77 22 12 73
Citation:
1. Tannery and pollution by Aloy M et al CTC 1976 p.307
2. Essais en station pilote d'ultrafiltration de bains residuaires de 1' Industrie du cuir by Vulliermet B et
al Technicuir 1976 v.6 p.94-99
3. Separation des proteines des proteines des dechets de peaux brutes par technique membrane by Dubois
M et al Technicuir 1978 v.4 p.53-63
Rhone-Poulenc Membrane Division
24 Quai Paul Doumer
92408 Courbevoie Cedex
Fiance
Tel:(33)l 47 68 08 01
Keywords: Leather, Tanning, Lime Sulphide, Recycling, BOD/COD, Ultrafiltration, Ammonia
2-139
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***** DOCNO: DOCUMENT NOT AVAILABLE (401) *****
1.0 Headline: Stabilization of hides and skins using BSH (Blanc Stabilise Humide) or BSS (Blanc Stabilise Se)
processes improves sorting of hides and skins and uptake of chromium while reducing solvent or chrome
wastes.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Gavend G
CTC (Centre Technique Cuir Chaussure Maroquinerie
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:(33)78 69 50 12
Tlx:340 497
Fax:(33)78 61 28 57
4.0 Clean Technology Category
Technology Principle: Alternative to chromium; Less chloride required; Better uptake of chromium; Solid
waste benefits - chromium; Alternative to solvents; Less solvents required; Liquid waste benefit - solvents;
Liquid waste benefits - BOD/COD; Odor reduction; Better working conditions; Chrome free by-product.
10-15% better uptake chrome in tanning process. No solvent for sheep skin degreasing.
Used in: Beamhouse, Tanning & Other
Cleanness: Good - best available to-date
BSH process can make important reduction in chrome wastes (solid and liquid). Better valorization is possible
in comparison with chrome solid waste (shavings). BSS process gives the possibility of solvent-free, or
"freon"-free degreasing. BSH and BSS improve the sorting of hides and skins.
5.0 Case Study Summary
Stage of Development: Widespread use 51-100 estimated number of enterprises in year 2000 5m sq ft+ of
leather produced to date
Level of Commercialization: 3 years in commercial use. Available: Europe, N. America, Australia & NZ
& Asia. First developed in: 1986
Results of Application: Stage of preparation of hides and skins which presents: - potential diversification of
the pickle without the acidity - stability of the wet blue without the problem of chrome use. It is a non-chrome
process using the low tanning effect of complexed aluminum salts.
6.0 Economics: Not reported
7.0 Cleaner Technology Benefits
Wastes: Utilization of chrome tanning on BSH increases the fixation of about 10-15 % of Cr2O3. Splitting and
shaving of BSH give the possibility of considerable reduction of chrome solid wastes in tanneries. Degreasing
of BSS is possible with water only and some surfactants. Chrome free by-product. 10-15% better uptake
chrome in tanning process. No solvent for sheep skin degreasing.
2-140
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8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Undesirable effects on the environment - possibly in the future (Aluminium)
9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Gavend G
CTC (Centre Technique Cuir Chaussure Maroq
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:(33)78 69 50 12
Tlx:340 497 Fax:(33)78 61 28 57
Industry/Program Contact and Address:
Balas A
Tanneries Grosjean
88160 Le Thillot
France
Tel:(33)29 25 00 07
Tlx:960 193
Fax:(33)29 25 81 29
Citation:
1. Bleu ou Blanc by Balas A. Industrie du Cuir 1988 (8802) p.27-29.
2. Elimination of salt pollution : Coupling of cooling of hides and wet white technology by Vulliermet B
& Gavend G. JSLTC 1988 72 2 p.68-72.
3. Nouvelle matiere premiere pour Findustrie du cuir, le BSS - Aspects fondamentaux by Haran R &
Gervais-Lugan M. Industrie du Cuir 1989 (8901) p.28-32
Regulatory Compliance: CTC Patent n deg 87-02035 du 11/oc/1987
Keywords: Leather, Tanning, Chromium, Chemical Alternatives, Stabilization, COD/BOD
2-141
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***** DOCNO: DOCUMENT NOT AVAILABLE (402) *****
1.0 Headline: Chilling of fresh (bovine) hides using cold air reduces salt in waste by 50%.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Gavend G
Centre Technique Cuir Chaussure Maroguinerie
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:+33 78695012
Tlx:340497
Fax:+33 78612857
4.0 Clean Technology Category
Technology Principle: Alternative to chloride; Liquid waste benefit - chloride; Solid waste benefits - chloride;
Alternative to biocide; Liquid waste benefit - biocide; Liquid waste benefits - total solids; Odor reduction;
Better working conditions; About 50% less chloride in effluents.
Used in: Rawstock
Cleanness: Good - best available to-date
Hides are free of salt or other chemicals and the possibility of valorization of by-products is better. It is
possible to have a specific enzymatic process at the beamhouse stage (sulphide free unhairing systems on
chilled hides).
5.0 Case Study Summary
Stage of Development: Limited commercial use 11-50 estimated number of enterprises in year 2000. l-5m
sq ft of leather produced to date
Level of Commercialization: 5 years in commercial use. Available: Europe, N. America, Australia & NZ.
First developed in: 1988
Results of Application: Preservation of fresh hides using cold air system with the possibility of antiseptic
additives (level 2 degrees C to +2 degrees C). Optimization of manipulation of fresh and chilled hides, with
diminution of labor costs. Adaptation and simplification of beamhouse process.
6.0 Economics
Investment Costs: Implementation costs: #10001-50000
Payback Time: 2 years
7,0 Cleaner Technology Benefits
Wastes: Suppression of salt in waste of curing units (liquid and solid). Important diminution of salt pollution
in tanneries (about 50 to 60%).
2-142
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S.O Obstacles, Problems and/or Known Constraints
Problems Encountered: Technical problems
9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Gavend G
CTC
France
Haefele C
4 rue Hermann Frenkel
69367 Lyon Cedex 07
France
Tel:+33 78695012
Tlx:340497
Fax:+33 78612857
Citation:
1. Elimination of salt pollution: coupling of cooling of hides and wet white technology, Vulliermet B &
Gavend G, JSLTC, 1988, 72, (2), 68-72.
2. The OCS chiller, Mattson G & Tomoser T, Leather Manufacturer, 1988, 4, 24-26
Keywords: Leather, Tanning, Process Alternatives, Hide Chilling, Waste Reduction, Chloride (Salt)
2-143
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***** DOCNO: DOCUMENT NOT AVAILABLE (403) *****
1.0 Headline: Finishing leather using ICC (Instant Colour Concept) process improves efficient use and reduces
wasting of chemicals.
2.0 ISIC Code: Not provided
3.0 Name and Location of Company:
Gavend G
CTC
4 rue Hermann Frenkel
69367 Lyon Cede* 07
France
Tel:+33 78695012
Tlx:340497
Fax:+33 78612857
4.0 Clean Technology Category
Technology Principle: Alternative to solvents; Liquid waste benefit - solvents; Liquid waste benefits -
BOD/COD; Odor reduction; Energy saving; Better working conditions; Other environmental claims/air
pollution decrease. Non-solvent finishing. Nearly 100% use of finishing materials.
Used in: Finishing Energy usage
Cleanness: Good - best available to-date
Utilization of ICC process allows the best utilization of chemicals (no waste). It is a solvent free process.
5.0 Case Study Summary
Stage of Development: Limited commercial use 51-100 estimated number of enterprises in year 2000. -1m
sq ft of leather produced to date
Level of Commercialization: 2.5 years in commercial use. Available: Europe, N. America, Australia & NZ,
S. America. First developed in: 1987
Results of Application: Process of finishing of leather using UV reticulation of specific chemicals (UV
curable polymers). This process is specially adapted for finishing of leather precuts for shoe manufacturing.
6.0 Economics
Investment Costs: Implementation costs: #50001-100000
Payback Time: 2 years
7.0 Cleaner Technology Benefits
Wastes: Total suppression of solvent emissions in the air. All the chemicals disposed on the leather are
transformed in a finishing film after UV curing. Air pollution decrease. Non-solvent finishing. Nearly 100%
use of finishing materials.
8.0 Obstacles, Problems and/or Known Constraints
Problems Encountered: Technical problems. Choice of finishes.
2-144
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9.0 Date Case Study was Performed: 1990
10.0 Contacts and Citations
Abstractor and Address:
Gavend G
CTC
France
Industry/Program Contact and Address:
Vitteau B
CTC
Citation:
1. The challenge of ICC (Instant Colour Concept). Zero stock level and zero delay, by Vulliermet B,
Vitteau B & Gavend G, Proc IULTCS Conf, Philadelphia, 1989, L-14.
2. Le challenge d'ICC - Zero stock, zero delai, by Vitteau B, Gavend G & Vulliermet B, Industrie du
Cuir, 1988, 8807, 81-83.
CTC Patent No 87 09163, January 23, 1987.
Keywords: Leather, Tanning, Leather Finishing, Alternative Chemicals, Solvent, Ultraviolet (UV) Curable
Polymers, Air Emissions
2-145
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***** Document No. 453-001-A-QOO *****
1.0 Headline: New tanning process reduces chromium use and waste in the leather tanning industry
2.0 SIC Code: Leather Tanning and Finishing/3111
3.0 Name and Location of Company:
British Leather Company
Tranmere Tannery
Birkenhead L41 9BS, England
4.0 Clean Technology Category: The tanning process was modified by using a two-stage process and metal
combinations to allow a smaller amount of chromium to be used.
5.0 Case Study Summary
S.I Process and Waste Information: The level of trivalent chromium normally used as a tanning agent for
high quality leather is between 4-5 percent by weight. With even the most efficient processing some
30% of the chrome offered to the hide is left in the tanning liquor.
The new technology employs a two stage tanning process. The first stage uses the 1CI 'TAL' process:
the liquor is based on titanium, aluminum and magnesium. In the second stage, a chromium tan is used
with 9 percent chromium instead of the normal 17 percent chromium. This results in a leather with a
chromium content of about 3 percent but with characteristics comparable to traditional leather.
5.2 Scale of Operation: The company employs over 300 people at two tanneries and processes about 6,000
hides per week.
5.3 Stage of Development: The technology is fully operational.
5.4' Level of Commercialization: The technology is commercially available.
5.5 Material/Energy Balances and Substitutions: The technology reduces the chromium content of the spent
liquor from 1,200 to 350 ppm and the level in the final effluent to 10 ppm.
6.0 Economics*
6.1 Investment Costs: Considerable research was carried out to identify the optimum tanning properties
of the various combinations of metals used in the first stage of the process. No new capital equipment
or investment is needed and the technology can be used with the existing plant.
6.2 Operational and Maintenance Costs: The company saved 160,000 English Pounds that it would have
cost to install the wastewater treatment equipment required to achieve the same chromium effluent
concentration achieved by the process change. A modest savings in tanning reagent costs is reported.
6.3 Payback Time: No information provided.
7.0 Cleaner Production Benefits
The main incentive to develop the new technology was an anticipated tightening of future wastewater
discharge standards. The chromium level in the discharge is substantially reduced by this technology.
2-146
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8.0 Obstacles, Problems and/or Known Constraints
None reported
9.0 Date Case Study Was Performed
Unknown
10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication.
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p4.
10.3 Level of Detail of the Source Material: Simple diagram of process provided.
10.4 Industry/Program Contact and Address: Arthur Jones, Production Director, The British Leather Co.
Ltd, Tranmere Tannery, Birkenhead L41 9BS, England, Telephone (051) 647-6252.
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation, 7600-A
Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Chromium wastes, spent tanning liquor
11.2 Process type/waste source: Tanning
11.3 Waste reduction technique: Process modification, source reduction, raw material substitution
11.4 Other keywords: United Kingdom, SIC 3111
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chromium Wastes, Spent Tanning Liquor, Tanning, Process Modification, Source Reduction Raw
Material Substitution, United Kingdom, SIC 3111
2-147
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Chrome Recovery and Recycling in the Leather Industry Using Precipitation Technology
2.0 SIC/ISIC Code: 3111
3.0 Name and Location of Company:
Germanakos SA, near Athens, Greece
4.0 Clean Technology Category: Tanning of animal hides is performed with chromium sulfate at a pH of 3.5-
4.0. This technology uses pH adjustment of the spent chrome tanning solution with magnesium oxide to
a pH of 8.0 to precipitate chromium. This precipitate is then dissolved in concentrated sulfuric acid at a
pH of 2.5. The liquor is now available for reuse in the tanning process.
5.0 Case Study Summary:
5.1 Process and Waste Information: Tanning of animal hides is a process that uses trivaient chromium
to turn the hides into a stable material. Approximately 20-40 percent of the chromium used in the.
tanning process is discharged into wastewaters. However, recent limits for discharge have limited
chromium discharge to as low as 2 mg/1 in the wastewater discharge. Using the new process, 95-
98 percent of the waste chromium can now be recycled.
5.2 Scale of Operation: Full-scale operation processing 2,200 tons of good quality upper leathers per
year.
5.3 Stage of Development: Fully scale Research and Development project.
5.4 Level' of Commercialization: This technology was developed by the Toegepast
Natuurwetenschappelijk Ondersoek (TNO), the Netherlands organization for applied scientific
research and carried out by their Institute of Environmental and Energy Technology.
6.0 Economics*
6.1 Investment Costs: $40,000 US includes a collection pit and a treatment tank with a stirrer.
6.2 Operational and Maintenance Costs: $30,200 US annual operating costs but provides an annual
savings of $73,750 US for a total net savings of $43,150 per year.
6.3 Payback Time: 11 Months.
7.0 Pollution Prevention Benefits
Implementation of the recovery and reuse technology requires very little change to the existing production
process and provides more consistent product quality. Also, this technology allows for easier water and
chemical monitoring and a much reduced chromium content in the effluent discharge.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: 1988-1990.
2-148
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10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Chrome Recovery and Recycling in the
Leather Industry," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mr. D. Papakonstantinou, General Manager, Hellenic
Leather Center SA, Thiseos 7a Street, 17676 Kallithea, Athens, Greece, Tel: +30 1 9025 595
Mr. Rob Glaser, Inspector International Affairs, Ministry of Housing, Physical Planning and
Environment, P.O. Box 7073 4330 GB, Middleburg, The Netherlands, Tel: +31 1180 33792
Mr. M van Vliet (Ex TNO), British Leather Confederation, Kings Park Road Moulton Park,
Northampton NN3 1JD UK, Tel: +44604494131
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Chromium leather tanning
11.3 Waste Reduction Techniques: Recovery, Reuse
11.4 Other Keywords: Greece
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Chromium leather tanning, Recovery, Reuse, Greece
2-149
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***** DOCNO: 400-054-A-241 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
Wastes:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Trivalent chromium recovered from effluent and reused in tanning process.
Manufacture of Leather/SIC 3111
Institute for Leather and Shoe Research/tonNO; Ministry of Public Health
and Environmental Protection of the Netherlands
The company removes trivalent chromium from the effluent and re-uses it
in the tanning process. The mean concentration of chromium (III) in the:
effluent is 5 kg/m3. This effluent is treated with MgO, producing a
fast-settling and compact precipitate, Cr(OH>3. The chromium (III)
concentration in the effluent is thus reduced to 2 g/m3 (a reduction of more
than 99 percent). The Cr(OH)3 is then dissolved in sulfuric acid for re-use:
in the tanning process.
Tanning process effluents containing chromium (III), sodium sulfate,
sodium chloride, and organic salts.
Effluent containing 1 g/m3 trivalent chromium, 40 kg sludge/ton of hide
material generated on sand filters.
Aqueous
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
The advantages of the technology include a less pollution effluent and a 40
percent saving in the chromium required for tanning.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recovery and Re-Use of Trivalent
Chromium in the Leather Tanning Industry", Monograph
ENV/WP.2/5/Add.54.
Leather Tanning, Chromium, Precipitation, SIC 3111
2-150
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METAL PRODUCTS MANUFACTURING
Hardening
Machining
Pickling
-,' " Painting
-------
-------
Hardening
***** DOCNO: 400-071-A-308*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Spinning rings hardened on a fluidized bed dry process eliminates waste
production.
Manufacture of Metal Products, Machinery and Equipment/ISIC 38
This audit of manufacturer of spinning rings, used in the textile industry,
suggests that by replacing the conventional cyanurated salts bath followed
by rapid oil cooling hardening process with a dry process on a fluidized bed
there is almost no waste generated. Baskets containing parts to be hardened
are dipped into a fluidized bath of nitrogen and corundum particles at
temperature between 840 and 860 degrees C. Baskets are then dipped into
another fluidized bath at 50 degrees C. Corundum left on processed parts
is recovered and recycled.
0.4 kg of corundum, 25 m3 of nitrogen and 0.63 GJ of electricity per 1000
spinning rings.
Negligible amount of dust
Fluidized bath of nitrogen and corundum particles
(Annual production of 300,000 spinning rings)
FF 185,000 (1979 figures)
60% of the O&M costs for the standard technology (excluding treatment
plant operating costs).
Not reported
FF 125,000 (1979 figures, including the capital cost for the treatment
plant).
Corundum left on processed parts is recovered and recycled.
The polluting wastes generated by the standard technology: used cyanurated
salts, oil fumes, and rinse water at a pH of 12.5 (3.5 m3 per 1,000 rings,
containing 75 Equitox) are completely eliminated.
This technology is more flexible in its application than the standard
technology.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Hardening of Spinning Rings by a Dry
Process on a Fluidized Bed", Monograph ENV/WP.2/5/Add.71.
Textiles, Metal Hardening, ISIC 38, Fluidized Bed, Corundum, Recovery,
Recycling
2-151
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***** DOCNO: 400-008-A-199 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Energy saved by use of Zinquench process.
Hardening and Zinc-Coating of High-Strength Bolts, Chains and Wire
Components/ISIC 3710
Oy Navire Ab, SF-21600 Parainen, Finland
Mr. Pentti Sippola
The Zinquench process is a continuous hardening and zinc-coating process.
In the Zinquench process the main stages are (1) austenitizing at normal
hardening temperature (approx. 900° Q, (2) quenching in zinc bath where
the hot-dip coating simultaneously takes place at 400° C, (3) ceutrifiiging
and finally (4) water cooling.
Not reported
Not reported
$900,000
$115/g
Not reported
$95/g
Not reported
Not reported
The process saves energy. Only about 40 per cent of the energy for
conventional technology is needed (60 per cent energy savings).. These
savings result from the tempering furnace not being used in the process and
the zinc bath not requiring a constant heat supply.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Continuous Hardening and Zinc-Coating
(Zinquench)", Monograph Env/WP.2/5/Add.8
Metal Hardening, Zinc Galvanization, Metal Treating, Zincqueach, ISIC
3710.
2-152
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Machining
***** DOCNO: 400-072-A-309*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Ultrafiltration of spent cutting fluids allows reuse of oil and reduces disposal
volume of spent oils.
Manufacture of Metal Products, Machinery and Equipment/ISIC 38
Ultrafiltration may be used to reduce the volume of spent cutting fluids
generated from cold machining. The spent cutting fluids are first processed
through a magnetic filter and a paper filter before Ultrafiltration. The latter
process ensures filtration at the molecular level because molecules of
pollutants are generally larger than those of active products. The filtrate is
then submitted to a quality test. If highly contaminated, the filtrate is
incinerated. If not, it is recycled. The standard process does not include
Ultrafiltration.
Spent cutting fluids
Filtration solids, filtrate (if highly contaminated)
Spent fluids
FF 200,000 (1976 figures)
Not reported
Not reported
FF 142,700 per year (1980 figures)
476 m3 of cutting fluids with the low-waste technology (versus 993 m3)
Eliminates disposal of 24 m3 of cutting fluid.
The volume of filtrate to be incinerated is reduced.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Cold Machining with Recycling of Cutting
Fluids after Ultrafiltration', Monograph ENV/WP.2/5/Add.72
Machining, ISIC 38, Ultrafiltration, Recycling, Cutting Oil
2-153
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***** DOCNO: 400-036-A-225 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Rinse waters reused and need to detoxify nitric acid baths eliminated in
etching process.
Manufacturing of Metal Objects, Machines and Material/ISIC 3819
Ministere de 1'Environnement et du Cadre de Vie
Direction de ia Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
In the low pollution technique, the brass parts to be treated are first placed
in a vibration apparatus with abrasive glass marbles and slightly acid
additive. After rinsing, the parts are placed in a second apparatus for
etching with steel balls and basic additive, then they are dried.
Brass parts
The wastes produced by the low pollution process are made of used baths
of acid reagents, which are sent for detoxification. The rinse water is
mixed with the baths of basic reagents. The mixture is then stored for pH
control, filtered to eliminate heavy particles, and sent back into the circuit.
Water, Air
(1979 Francs)
F 265,000
Not reported
Not reported
Not reported
Not reported
Not reported
The low pollution technique eliminates the need to detoxify nitric acid baths.
perform soda neutralization of nitric vapor, and treat rinse waters
Not reported
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Descaling of Metal Objects by means of
Vibration/Abrasion", Monograph ENVAVP.2/5/Add.36.
Process Change, Abrasive Cleaning, 1SIC 3819
2-154
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Pickling
***** DOCNO: 400-097-A-322*****
HEADLINE:
INDUSTRY/ISIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Regeneration and copper recovery of sulfuric acid pickling baths is
accomplished by recycling the rinse water back to the copper pickling
process instead of detoxication.
Non-ferrous Metal Basic Industries/ISIC 3720
Regeneration and copper recovery of sulfuric acid pickling baths is
accomplished in a continuous electrolysis process. Part of the rinsing water
is recycled to the copper pickling process, and the remaining part is
detoxicated. Current technology requires detoxication of the chemical baths
and all of the rinsewaters.
Electrical energy - 3.2 MJ, Sulfuric acid
Rinse water containing 40 g of copper and 50 g of free acid per ton of
copper
Water
140,000 francs (1977 franc) for pickling 12,000 tons of copper
Additional operating expenses are considerable lower than revenues from
selling the copper, and savings in sulfuric acid and running cleaner
operations
Not reported
Revenues from sales of 200 g of copper/ton processed
Reduction in sulfuric acid requirements
Rinse water is reduced in volume, copper content is reduced by 210 g, and
free acid is reduced by 450 g
This recycling technology significantly limits the volume of wastes requiring
detoxication while recovering sulfuric acid feed, and copper for resale.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Pickling of Copper Parts: Electrolysis of
Used Pickling Baths", Monograph ENV/WP.2/5/Add.97.
Nonferrous Metal, Pickling, Recycling, Electrolysis, ISIC 3720
2-155
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Painting
***** DOCNO: 450-003-A-358*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Moyer Diebal replaced liquid paint system with powder coating process,
eliminated paint sludge, and reduced energy consumption.
Machinery/ISIC 38
Moyer Diebel
Jordon, Ontario
G. Evans
An automated powder coating process is used in a small paint line in the '
manufacture of vending machines. It was found that the powder coating
sticks better and requires less cleaning. As a result, the company was able
to reduce its 4-stage prewash system to 3 stages. An efficient overspray
system allows for 95-99% of the 5,000 Ibs of powder used each month to
be used for coating. Thus, the company does not accumulate paint sludge
wastes.
Powder coating
Waste feed materials, rinsewater
Powder, sludge
$280,000
15 % lower than a liquid paint line.
Not reported
Not reported
Reduced paint requirements due to improved efficiency, 35% less energy
required.
Reduction in prewash stages reduces wastewaters, efficient powder use
eliminates paint sludge.
A more efficient, dry powder paint line allows for reduced raw material
requirements and reduced waste generation.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects",
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment:
Canada, March, 1987, page 58.
Paint, Coating, ISIC 38
2-156
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Waste Reduction in Steelwork Painting Using Airless Spray and Pressure Atomized Electrostatic
Spray Paint Systems
2.0 SIC/ISIC Code:
3.0 Name and Location of Company:
Ostrowiec Steelworks, Poland
4.0 Clean Technology Category: The facility evaluated the improved efficiency of using airless spray and
pressure atomized electrostatic spray paint systems over the existing air atomized system. The efficiency
of painting improved from 30-50 percent to 85-90 percent for the pressure atomized electrostatic spraying.
Implementation of the more efficient painting operation reduces waste disposal and raw material purchases.
5.0 Case Study Summary:
5.1 Process and Waste Information: The facility originally carried out painting operations using an air-
atomized spray system that has the lowest transfer efficiency of the coating methods and yields large
quantities of waste. The facility conducted a pollution prevention audit to reduce the quantity of
wastes and costs of painting by a combination of improvements to the technology and good
housekeeping. The facility also wanted to improve the quality of the coating and to reduce the
amount of paint raw material. Comparison of the existing air-atomized painting system with two
'. more efficient methods (airless spray and pressure atomized electrostatic spray) identified more
efficient methods for applying paint.
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: The two spray systems were tested at a full-scale steel manufacturing
facility.
5.4 Level of Commercialization: The airless spray and pressure atomized electrostatic spray systems
are readily available.
5.5 Material/Energy Balances and Substitutions:
Paints
Solvents
Wastes
Air-atomized spray
8.0m3
6.5m3
2,400 kg
Airless Spray
6.8m3
1.6m3
' 1,400kg
Pressure Atomized
Electrostatic Spray
5.6m3
1.6m3
500kg
6.0 ' Economics*
6.1 Investment Costs: The capital investment of the airless spray system is about US$4,800 while the
pressure atomized electrostatic spray system is about US$13,000.
6.2 Operational and Maintenance Costs: The cost savings from implementing the airless spray system
is about US$38,500 a year and US$39,400 for the pressure atomized electrostatic spray system.
6.3 Payback Time: 1.5 months for the airless spray system and 4 months for the pressure atomized
electrostatic spray system.
2-157
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7.0 Pollution Prevention Benefits
Modification to a higher efficiency painting operation reduces waste disposal costs, reduces operating costs;,
decreases financial liability of hazardous waste management, improves public perception and acceptance
in the business community, and also indicated potential reductions in the effluent concentrations of about
45 percent for sludge and 75 percent for organic solvents.
8.0 Obstacles, Problems, and/or Known Constraints
None Specified.
9.0 Date Case Study Was Performed: Not Identified.
10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Waste Reduction in Steelwork Painting,"
1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mrs Lucyna Chrzanowska, Steelworks 'Ostrowiec', ul
Swietokrzyska, 27-400 Ostrowiec Swietokrzski, Poland, Tel: +48 472 528 81
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Paint waste
11.2 Process Type/Waste Source: Painting, Iron and Steel
11.3 Waste Reduction Techniques: Process Modification
11.4 Other Keywords: Airless paint spray, Pressure atomized electrostatic paint spray
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Paint waste, Painting, Iron and Steel, Process Modification, Airless paint spray, Pressure atomized!
electrostatic paint spray
2-158
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Minimization of Organic Solvents in Degreasing Using Alkaline Cleaners and in Painting of
Metal Parts Using Electrostatic Powder Painting
2.0 SIC/ISIC Code:
3.0 Name and Location of Company:
Thorn Jamkonst, Sweden
4.0 Clean Technology Category: Thorn Jamkonst implemented two changes to provide for cleaner production.
First, the plant installed a five stage washing/phosphating unit to degrease the metal parts and prepare the
surface for painting. The degreasing is carried out in a tunnel 30 meters long with the metal parts
suspended from an overhead conveyor and then passed through five zones where they are sprayed with an
alkaline degreaser, a water rinse, an iron phosphate solution, another water rinse, and a deionized water
rinse. The liquid runs off the metal parts and into tanks below where it is recirculated back to the spray
nozzles. Second, the plant installed an electrostatic powder painting unit using polymer based paints that
do not have any solvent in their formulation. The system has twelve automatic powder guns. The paint
is positively charged relative to the metal parts. Now only 5 percent of the colors have organic solvents
and are used only for the painting of short production runs in special colors or for retouching of the
automatically sprayed items. Manual spraying is carried out in a ventilated booth fitted with two
electrostatic guns.
5.0 Case Study Summary:
5.1 Process and Waste Information: Thorn makes light fittings from aluminum or steel sheets. Metal
working, degreasing, and painting are the main phases of the production process. In the past,
degreasing was performed using trichloroethylene. The painting plant consisted of an automatic
lacquer line, with different colors using different organic solvents. The plant determined that
adequate degreasing could be achieved using an alkaline cleaning process while electrostatic painting
could be used for coating the metal parts. In addition, color changes were simplified using whole
modules with containers of different colors.
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: These practices are fully implemented at the Thorn Jamkonst facility.
5.4 Level of Commercialization: The 5-stage degreasing equipment is available from Br Michaeisen
AB, Kunglav, Sweden. The automatic powder painting equipment is available from Gema-Volstatic
AG, St Gallen, Switzerland. The manual powder painting equipment is available from Eisenmann
AG, Boblingen, Germany.
5.5 Material/Energy Balances and Substitutions: The facility went from emitting 11 tons of
trichloroethylene to the air and 5 tons of trichloroethylene sludge from the degreasing operations
to less than 2 tons of sludge and no air emissions. The modification of the painting techniques
resulted in the reduction of organic solvent air emissions from 65 tons to 7 tons a year and reduced
hazardous waste generation from 10 m3 solvents, 47 tons color residue, and less than one-half ton
of powder residue to 2 m3 solvent, 0.2 tons color residue, and 3 tons of powder residue.
6.0 Economics*
6.1 Investment Costs: Capital investment costs amounted to US$430,000. This includes the 5-stage
degreasing and the electrostatic painting equipment.
2-159
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6.2 Operational and Maintenance Costs: The alkaline degreasing operation is US$25,000 a year
cheaper than the trichloroethylene degreasing system and did not require the installation of recovery
equipment. The powder painting techniques have provided the following cost savings: paint-
$206,000, cleaning-$62,000, disposal-$47,000, pumping-$33,000, and labor-$ 112,000.
6.3 Payback Time: 11 months for the powder painting operation.
7.0 Pollution Prevention Benefits
The elimination of solvent degreasing reduces both air emissions and hazardous waste generation. The
changed painting technique provides a large reduction of the discharge of organic solvents, reduction of
hazardous waste, improved work environment, and the ability to expand production without conflicting with
environmental demands.
8.0 Obstacles, Problems, and/or Known Constraints
None Identified.
9.0 Date Case Study Was Performed: Not Specified.
10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Minimisation of Organic Solvents in
Degreasing and Painting," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Egon Conradi/Lars Blomqvist, Thorn Jamkonst AB, P O
Box 305, S-261 23 Landskrona, Sweden, Tel: +46 418 52000
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Air emission, hazardous waste
11.2 Process Type/Waste Source: Organic solvent degreasing, organic painting solvents
11.3 Waste Reduction Techniques: Process modification, Material substitution
'11.4 Other Keywords: Electrostatic powder painting, Alkaline degreasing
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
2-160
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Air Emissions, Hazardous Waste, Organic Solvent Degreasing, Organic Painting Solvents, Process
Modification, Material Substitution, Electrostatic Powder Painting, Alkaline Degreasing
2-161
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***** DOCNO: 400-032-A-221 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Solvent recovery using activated carbon and steam cleaning.
Manufacturing of Metal Products, Machines and Material/ISIC 3819
Ministere de FEnvironnement et due Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The facility is involved with priming and lacquering aluminum foil. In the
low pollution technique, the solvent vapors emitted during the hot air drying
of the lacquer are recovered with activated carbon. The activated carbon,
in a second operation, is steam cleaned. The solvent vapor and water vapor
. mix is sent into a distilling column after condensation. After condensation,
the solvents obtained are recycled to the workroom where the lacquer is
prepared. In the standard process, the solvent vapors from the drying of
the lacquer are discharged directly into the atmosphere without treatment.
This is the first industrial application of the recovery of ketonic solvent
vapors, generally considered as a difficult procedure. As the technical
results were positive as far as the reduction of pollution is concerned and
the economic results should be satisfactory given the expected increase in
the prices of petroleum based solvents, the use of this process should be
extended to activities employing the same types of products.
Solvent vapors
The waste produced is made up of ketonic and ethylic solvent vapors.
Air
(1978 Francs)
F 3.85 million
Not reported
Not reported
Not reported
Not reported
Virgin solvent requirements reduced by a factor of three.
With the low pollution technique, 30 kg of solvent vapors are released into
the atmosphere per ton of solvent used. With the standard technique, the
quantity of the waste released is 700 kg.
The amount of new solvents required is reduced by three due to recycling.
Energy needs are increased by 13.5 GJ per ton of solvent used in order to
produce the vapor necessary for cleaning the activated carbon and the
distillation of the recovered solution.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recovery and Recycling of Solvents from
Vapors Originating from Priming and Painting of Aluminum Foils",
Monograph ENV/WP.2/5/Add.32.
Solvent, Air Drying, ISIC 3819, Activated Carbon, Distillation
2-162
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MINING
-------
-------
***** Doc # 501-016-A-OOO *****
1.0 Headline: Thin layer process of copper and uranium ore-leaching cuts water use by up to 75 % and reduces
dust generation.
2.0 SIC Code: SIC 1021, SIC 1094, Copper ores/Uranium-radium-vanadium
3.0 Name and Location of Company:
Sociedad Minera Pudahuel, Ltda.
Santiago, Chile.
4.0 Clean Technology Category
This technology involves using thin-layer (TL) leaching to process ores using less water, thereby reducing
tailings volume.
5.0 Case Study Summary
5.1 Process and Waste Information: The Thin Layer (TL) process involves spreading the crushed ore
in layers 3 ft. thick or less for leaching. After treatment with concentrated sulfuric acid, which
liberates the copper or uranium, the crushed ore is allowed to cure for a day. It is then spread over
shallow beds for leaching. The shallowness of the beds permit uniform contact between the leach
liquor and the ore by minimizing compacting and channeling. In agitation leaching, the
conventional copper and uranium process, tailings are typically mixed with about 50 wt. % of water
for disposal. In the TL process, water use may be as little as one-fourth the amount needed for
agitation leaching.
5.2 Scale of Operation: The operation was expected to handle 2,600 metric tons/day of copper ore.
5.3 Stage of Development: Ore has been processed in bench tests and at an 8-ton/day uranium ore
demonstration plant in Moab, Utah. Full scale implementation was scheduled for late 1979.
5.4 Level of Commercialization: The technology is commercially available.
5.5 Material/Energy Balances and Substitutions: This technology uses 25 percent less water than the
conventional leaching method.
6.0 Economics*
6.1 Investment Costs: The investment is $30 million ($1,875 per annual ton of copper produced based
on 355 production days/year) for the leach, solvent-extraction and electrowinning sections. Figures
are in US dollars and based on 1978 prices. There is a 50% cost savings compared to an agitation
leach facility. The comparison only includes the mill section.
6.2 Operational and Maintenance Costs: A 5% to 15% reduction in operating costs are expected
compared to agitation extraction. A 40 to 60% smaller solvent-extraction plant is required because
the metal concentration in the leach liquor can be controlled to a higher concentration than in
agitation leaching. Tailing disposal costs are lower because tailings take up only 25% of the
volume compared to tailings from agitation leaching methods.
6.3 Payback Time: Not reported
2-163
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7.0 Cleaner Production Benefits
Economic benefits from reduced water use are expected. The tailings have about one-fourth those generated
using the conventional process. Less fugitive dust is generated because the TL process only requires ore
to be crushed to 3/8 inch size versus <65 mesh for cooper and <28 mesh for uranium so there are fewer
fines, minimizing windblown dust.
8.0 Obstacles, Problems and/or Known Constraints
None were identified.
9.0 Date Case Study Was Performed
April 1978
10.0 Contacts and Citation
10.1 Type of Source Material: Book.
10.2 Citation: Process Technology and Flowsheets, articles which appeared in Chemical Engineering
over the last five years. V. Cavaseno and Staff of Chemical Engineering, McGraw-Hill, NY, NY,
1979. Cu/U ore-leaching route cuts pollution, trims costs, Gerald Parkinson. Pg. 108.
10.3 Level of Detail of the Source Material: Detailed process information and flow sheet provided.
10.4 Industry/Program Contact and Address: Holms & Naver, Inc., 999 Town and country Rd.,
Orange, CA 92668.
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: mine tailings, slurry
11.2 Process type/waste source: Metal mining, cooper ores, uranium ores
11.3 Waste reduction technique: process redesign, volume reduction thin-layer (TL) process
11.4 Other keywords: volume reduction, SIC 1021, SIC 1094
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Mine Tailings, Slurry, Metal Mining, Copper Ores, Uranium Ores, Process Redesign, Volume
Reduction Thin-Layer (TL) Process, Volume Reduction, SIC 1021, SIC 1094
2-164
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NONFERROUS METALS
-------
-------
***** DOCNO: 400-069-A-306*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Copper pickling operation uses alcohol instead of acid and eliminates acid
dumps and rinsewater discharges.
Metallurgical Industry/ISIC 38
A pickling of copper wire process which utilizes alcohol produces no
pollutant discharge. The wire rod, hot and slightly oxidized, leaves the mill
and enters a pickling chamber fed with alcohol which reduces copper oxides
present in metal form. In the standard technology the pickling process is
achieved with a similar installation, but acid is used to dissolve the oxides
and the metal. It is then necessary to rinse with water.
Alcohol
None
Liquid
FF 300,000
FF 8.55 per ton of pickled wire
Not reported
Not reported
With the low-waste technology pickling one ton of wire requires 4 liters of
alcohol solution, versus 2 kg of H2SO4 at 66 degrees. With the standard
technology. Furthermore, the standard technology requires 750 liters of
rinse water and 0.75 kg of effluent-neutralizing products.
There is no polluting discharge with the low-waste technology. The
standard technology generates 750 liters of waste per ton of pickled wire,
consisting of: 20 g of suspended matter, 15 g of oxidizable matter, and
toxicity = 0.3E. The neutralization process produces 2 kg of sludge per ton
of pickled wire.
The new process can be applied only to continuous casting and drawing
units. Alcohol pickling is only feasible when surface oxidation is light and
when the copper is at a temperature sufficiently high for the chemical
reaction to occur.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Pickling of Copper Wire with Alcohol.",
Monograph ENV/WP.2/5/Add.69.
Metallurgical Industry, IS1C 3800, Pickling, Alcohol, Copper
2-165
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***** DOCNO: 400-068-A-305*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Mechanical descaling of wire-rod coils eliminates hot acid bath discharges
and provides a more reliable and safer descaling process.
Metallurgical Industry/ISIC 38
The standard technology dips wire-rod coils in a hot acid bath, rinsed and
then treated with lime in order to neutralize any trace of acid. In the new
process, wire-rod is descaled by roller-binding. It then goes through a
sanding chamber where it is sand blasted. The surface quality thus achieve*!
permits wire-drawing. The low-waste dry and wet processes require 0.5 GJ
per ton of descaled wire-rod versus 2.35 GJ in the standard technology.
Water
Scale from the metal descaling operation
Solid
FF 500,000 (1979 figures)
FF 22.9 per ton (1979 figures)
Not reported
FF 26.6 per ton descaled.
3.99 m3 of water per ton of descaled wire-rod.
5 kg of scale
Greater safety and reliability due to the absence of hot acid.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Mechanical Descaling of Wire Rods by a
Dry or Wet Process", Monograph ENV/WP.2/5/Add.68.
Metal Finishing, Wire, Descaling, ISIC 38
2-166
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***** DOCNO: 400-098-A-260 *****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Blende transformed into zinc oxide by roasting to recycle SO,.
Non-ferrous Metals/ISIC 3720
This process transforms blende into zinc oxide by roasting with fabrication
of H2SO4 through catalysis of roasting gases and integrated treatment of tail
gases. The blende is roasted to obtain zinc oxide. The resulting gases are
sent, in succession, to a scrubbing unit, a catalysis unit and then to a
concentration column. Tail gases are treated and recycled. The resulting
sulphite mud is mixed with wastes from the gas scrubber, neutralized, and
settled.
Blende
Tail gases, sludge
Gaseous
(Francs 1980)
1,800,000
2 Francs per ton ZnO
Not reported
2 Francs per ton ZnO
The low pollution technique leads to the production of 1.037 tons of H2SO4
for one ton of ZnO.
The production of one ton of ZnO gives rise to the rejection of 3 kg
(against 22 kg for conventional technology) of SO, into the atmosphere.
The low pollution technique permits improving catalysis efficiency through
recycling of SO2 and thus transformation efficiencies to be obtained that are
comparable with that of the double catalysis process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Transforming Blends into Zinc Oxide by
Roasting With Fabrication of H2SO4 Through Catalysis of Roasting Gases
and Integrated Treatment of Tail Gases", Monograph ENV/WP.2/5/Add98.
Acid Catalysis, ISIC 3720, Tail Gases, Blende
2-167
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***** DOCNO: 400-095-A-320*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COSTS:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Brass turnings are recycled and heat is recovered from recycling process
reducing energy requirements.
Nonferrous Metal Basic Industries/ISIC 3720
Brass turnings are compressed and transformed into briquettes to reduce the
free area and to reject part of the oil contained in the turnings. Remaining
oil is removed by drying in an oven. Briquettes are then sent to a melting
furnace. Fumes are filtered and heat is recovered. With the standard
techniques, briquettes are sent directly to the melting furnace and resulting
fumes are not processed.
Per one ton of briquettes, 1.06 tons of turnings are required, 980 MJ of
electricity, 315 MJ of butane.
16,500 m3 of fumes are rejected containing 0.5 kg of unburnt residues
Gaseous
5,200,000 francs
650,000 francs/year (minus revenues of 780,000 francs)
Not reported
700,000 francs in additional sales of brass, 80,000 francs from energy
recovery (operating costs of low waste technology are 650,000 compared
to 200,000 francs/year for conventional technology, investment is 5,200,003
compared to 2,000,000).
Reduction of 0.03 tons of turnings, increased usage of energy consisting of
635 MJ electricity and 315 MJ butane.
16,500 m3 of fumes are rejected (compared to 3,700 m3 with conventional
technology) containing 0.5 kg unburnt residues (compared to 11 kg).
Significant reduction in concentration of unburnt residues in fume
emissions. Working conditions are also improved.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Melting of Brass Turnings in and Electric
Furnace with Previous De-oiling of Turnings and Heat Recovery",
Monograph ENV/WP.2/5/Add.95.
Nonferrous Metal, Energy Recovery, Gas Filtration, Brass Turnings, ISIC
3720
2-168
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*****DOCNO: 400-114-A-327*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
QSL Process, developed to smelt lead sulphide concentrates and sulphate
secondaries, reduces fuel requirements by 60% and waste gases by 80%.
Non-ferrous Metal Basic Industries/ISIC 3720
The QSL Process has been developed to smelt lead sulphide concentrates as
well as sulphate and mixed oxide-sulphate secondaries such as flue dusts,
battery paste or lead-silver residues. As in conventional lead smelting, the
gangue minerals contained in the raw materials are separated from the
molten metal in the form of a fluid siliceous slag. Instead of two separate
steps of sintering and blasting in a furnace, the QSL Process is a one-step
process of continuous smelting of the charge, with the resulting pellets
directly fed to the oxidation and reduction zones of the reactor. Sulphur
dioxide gas emissions of about 15 to 25 % by volume are utilized in the
manufacture of sulfuric acid. Any sulphur contained in reduction coal or
fuel is recovered, and the precipitated flue dust is directly recycled to the
mixing section.
Lead concentrate, fuel (coal), oxygen, nitrogen, fluxes, electrical energy
Air exhaust, dust, discarded slag
Gaseous, solid
DM 90-110 million
235 DM/ton lead bullion
Not reported
30 million DM in capital cost, 149 DM/ton lead bullion in operating costs
60% reduction in fuel consumption, recycling of precipitated flue dust
Waste gases are reduced from 20,000 to 25,000 m3/ton of lead (20 mg
dust/m3), to 4,000 to 5,000 m3/ton of lead (10 to 20 mg dust/m3). Sulphur
dioxide gas can be used in sulfuric acid production, instead of emitting to
the air.
The QSL Process is a continuous one-step process with low investment and
operating costs compared to the conventional technology. Energy recovery
reduces the fuel requirements by 60%, and sulphur contained in the raw
materials is recovered. The volume of waste gases emitted to the
environment is reduced by 80%, and the SO2 emissions are eliminated.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Continuously Operating Direct Lead
Smelting Process (QSL)", Monograph ENVAVP.2/5/Add. 114.
Nonferrous Metal, Lead, Smelting, QSL Process, Energy Recovery,
Reduction Furnace, Gas Collection, 1SIC 3720
2-169
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***** DOCNO: 400-009-A-200 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Ferrochrome process uses lower grade ores, recovers waste gases, and
reduces slag generation.
Ferrochrome Production and Raw Materials/ISIC 3710
Outokumpu Oy, SF-02200 Espoo 20, Finland
Mr. Bengt Norrman
Outokumpu Oy has developed a ferrochrome process, where chrome ore
fines and ores with a low chrome content can be used as raw material to
produce ferrochrome. Special attention has been paid to the environmental
aspects, when developing this process, and total energy consumption is low.
Ore fines or concentrate are first ground in a wet grinding mill with
grinding media to the fineness required for palletizing. Sludge from
grinding is filtered before pelletizing, which is performed by a palletizing
disc. The sintering of pellets takes place in the vertical shaft furnace at the
temperature of approximately 400° C. Its burners are designed to use
electric furnace CO-gases and coal mixed with the pellets. The sintering
pellets together with coke and slag forming materials are dosed into the
preheating furnace, where carbon monoxide from the arc furnace is used as
fuel. Preheated feed mixture is fed through the feeding ring continuously
into the totally closed electric smelting furnace. Waste gas from the furnace
is cleaned before use as a fuel in the sintering and preheating furnaces;.
Molten ferrochrome is granulated or cast into molds which are crushed after
cooling.
Furnace CO-gas is used in the sintering furnace of pellets and in preheating
the smelting charge.
From different stages of the process, dust recovered from waste gas
purifications is brought back to the process through pelletizing.
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Energy savings, use of lower grade ores and raw materials and reduced slag
and gas generation.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Outokumpu Ferrochrome Process".
Monograph ENVAVP.2/5/Add.9.
Ferrochrome, ISIC 3710, Energy Recovery
2-170
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PETROLEUM "REFINING
-------
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***** DOCNO: 400-046-A-235 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Petroleum Refining/ISIC 3530
The USSR State Committee for Science and Technology
The process of hydrodesulfurization is developed so that it can be used after
the de-asphalting of the residue with light gasoline. Heavy residual
products of sulfur and high sulfur crude petroleum is de-asphalted with light
gasoline (virgin gasoline) in standard extraction columns at a temperature
of 140-190° C and a dilution ratio of 3.5:1 to 5:1. The content of ash in
the de-asphalted oil compared with the feed stock will be 2-4 times less and
its coking tendency about 1.5-2 times less. In addition, 2-7 percent of the
feed is in the form of a new product - petroleum asphaltite - containing
60-80 percent asphaltenes, 10-20 percent of resin and 10-20 percent of oil.
The asphaltite is easily powdered and does not agglomerate in storage. The
product can be used for thermo/hydroisolation of heat tubes, and in
combination with vacuum residue it can be used to briquette coal fines and
to produce bitumens of different grades.
Not reported
Flue gases from process furnaces.
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Preconditioning of Petroleum Residues for
Subsequent Catalytic Processing and Manufacture of New Material:
Petroleum Asphaltite", Monograph ENVAVP.2/5/Add.46.
Petroleum, Asphaltite, ISIC 3530
2-171
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***** DOCNO: 400-045-A-234 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Petroleum Refming/ISIC 3530
The USSR State Committee for Science and Technology.
Sulfide-containing condensates are treated by means of distillation.
Distillation of sulfide-containing condensates makes it possible to produce
hydrogen sulfide and ammonia as products. The distillation unit allows the
production of 95-97 per cent gaseous ammonia and 98 percent hydrogen
sulfide. The effluent from the distillation unit contains 50-100 mg/1 of
hydrogen sulphide and around 500 mg/1 of ammonia. This wastewater is
either used in the pre-treatment unit or discharged into the sewer.
Sulfide-containing condensates
None
Aqueous
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Non-waste process gives commercial products of hydrogen sulfide and
ammonia.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Utilization of Process Condensate Resulting
from Petroleum Refining", Monograph ENV/WP.2/5/Add.45.
Petroleum Refining, Condensates, Distillation, 1S1C 3530
2-172
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' ' * ^PLASTICS PROCESSING'"
-------
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**** DOCNO: 400-038-A-227 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST*
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Pickling of ABS parts in concentration solution decreases acid consumption
and reduces detoxification needs.
Chemical industry and manufacturing of chemical products, petroleum and
coal derivatives and plastic and rubber products/ISIC 3560
Ministere de 1'Environnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
Pickling of ABS plastic matter in a sulfochromic solution with restoration
and recycling of the solution.
The pickling operation itself is identical to the standard technique except
that a basket containing the plastic parts is dipped into a bath of
concentrated sulfuric acid and chromic acid that ensures descaling. When
the Cr3+ ion concentration reaches 50 g/1, in the low pollution process, the
bath is restored by electrodialysis and recycled in order to maintain the
Cr3"h concentration at between 20 g and 30 g/1.
The restoration of the bath allows a reduction of sulfuric acid consumption
from 12.5 kg/100 m2 descaled to 3.3 kg and the consumption of chromic
acid from 13 kg/100 m2 descaled to 3.5 kg.
ABS plastic, sulfochromic solution
Sulfochromic baths sent for detoxification
Aqueous
F 100,000
Not reported
Not reported
F 76,000
Not reported
No information is available concerning the wastes produced by the
detoxification station. The baths sent for detoxification equal 9.5 1/100 m2
for the low pollution technique against 35 1 in the standard process.
Since the number of times the baths are sent to the detoxification center is
reduced by four, the risks of accidental pollution are reduced by as much.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Surface Treatment of Plastic Materials in
a Sulfochromic Solution with Regeneration and Recycling of the Solution",
Monograph ENV/WP.2/5/Add.38.
Pickle Liquor, ISIC 3560
2-173
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PRINTING
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***** Document No. 453-001-A-OOO *****
1.0 Headline: Use of water-based screen printing inks and radio-frequency dryers eliminate solvent emissions
and save energy.
2.0 SIC Code: 2700, Screen printing
3.0 Name and Location of Company:
Sericol Group Ltd.
Westwood Road
Broadstairs
Kent CT10 2PA, England
4.0 Clean Technology Category
This technology involves development of water-based screen printing ink to replace solvent-based ink.
5.0 Case Study Summary
5.1 Process and Waste Information:. Use of solvent-based inks results in fumes which are undesirable
to the work and outdoor environments. Heat generated during the drying process also contributes
to bad working conditions and to energy wastage.
Sericol developed a water-based ink whose performance is at least as good as the existing
solvent-based inks. Although water-based inks can be used with conventional dryers their full
potential is realized when radio-frequency (RF) dryers are employed. Using the microwave
principle only the wet, i.e., printed, areas are heated.
5.2 Scale of Operation: The company has a staff of over 500.
5.3 Stage of Development: The technology is fully operational.
5.4 Level of Commercialization: Water-based inks are commercially available.
5.5 Material/Energy Balances and Substitutions: Not reported
6.0 Economics
Not reported
7.0 Cleaner Production Benefits
Advantages include elimination of solvent use and atmospheric emissions. If radio frequency drying is
used, energy is saved and a higher drying speed can be obtained.
8.0 Obstacles, Problems and/or Known Constraints
None identified.
9.0 Date Case Study Was Performed
Unknown
2-174
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10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication.
10.2 Citation: Clean Technology, Environmental Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989, p!4.
10.3 Level of Detail of the Source Material: No additional detail is provided.
10.4 Industry/Program Contact and Address: David Seddon, Technical Director, Sericol Group Ltd.,
Westwood Road, Broadstairs, Kent CT10 2PA, England, Telephone (0843) 67071
10.5 Abstractor Name and Address: John Houlahan, Science Applications International Corporation,,
7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Solvent-based ink
11.2 Process type/waste source: Solvent emissions, printing ink
11.3 Waste reduction technique: Raw material substitution, radio frequency (RF) dryers
11.4 Other keywords: United Kingdom, air emissions, energy conservation, SIC 2700
Keywords: Solvent-Based Ink, Solvent Emissions, Printing Ink, Raw Material Substitution, Radio Frequency (RF)
Dryers, United Kingdom, Air Emissions, Energy Conservation, SIC 2700
2-175
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***** DOCNO: 400-109-A-324*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
Recycling of printing ink to be reused by newspapers as black printing ink
reduces waste disposal to treatment plant by seven tons.
Newspaper Production/ISIC 3420
Discarded printing ink is collected, purified, and reused as black printing
ink. Waste ink produced from the printing process and from color changes
is collected in an accumulation vessel and is passed through four filters, the
last of which removes particles down to 25 microns. The purified ink is
then mixed with new printing ink for reuse in newspaper production.
Waste ink with moisture content below 5% and other impurities such as oil
and organic solvents below 2%, 0.05 kWh energy consumption per ton
paper
Low volume of synthetic filters and objects from coarse filter
Solid
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
37,000 Danish kroner (1980)
1.23 Danish kroner per ton of paper
Not reported
3.0 Dk/ton of paper for destruction of discarded ink
21.5 Dk/ton savings for reusing the ink
7 tons of discarded printing ink is treated per year
7 tons of discarded ink requiring disposal in national treatment plant
Seven tons of waste no longer require waste disposal in a treatment plant.
With a net savings of 24.5 Dk per ton of paper, and about 185,000 tons of
paper used per year in Denmark, the possible savings are 4 - 5 miHion Dk.
Annual costs of printing ink are 50 to 60 million Dk (1980).
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Re-use of Printing Ink for Newspaper
Production," Monograph ENV/WP.2/5/Add.l09
Ink, Printing, Recycling, Filtration, 1SIC 3420
2-176
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PULP AND PAPER
Wood Pulp Mills
Nonwood Pulp and Paper Mills
• Synthetic Fibers Pulp Mills
; Paper Mills
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Wood Pulp Mills
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Decrease and control of environmental loads of a pulp mill with a new mill layout.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
CTS Engineering Oy, P.O.Box 193, SF-45101, Kouvola, Finland.
4.0 Cleaner Technology Category
Due to a centralized layout, consumption of electrical energy and heat can be decreased, and more power
is produced to the market if compared with a mill based on today's technology. Thanks to the chosen
technology, the degree of coloration, AOX emissions, and COD emissions are lower than in a conventional
solution.
5.0 Case Study Summary
5.1 Process and Waste Information
Conventional chemical pulp mill that produces fully bleached pulp consists of about twenty
departments that operate with different principles. The mill requires a lot of area. Subprocesses
are far from each other, it is difficult to follow and manage material flows. Disturbances in
production cause, besides reduced output, also environmental stress and decrease in product quality.
The target of the research work presented was to develop a chemical pulp mill that would be more
centralized, more economical of energy and ecologically more beneficial. A sulphate pulp mill that
uses pine as raw material was chosen as the basis for the survey. The result of the development
work is a preliminary plan for a sulphate pulp mill, basing on a round layout, sited in a coherent
roofed space. The mill is accommodated in a structural steel building. The soda recovery unit,
auxiliary boiler and deep tank aeration system are located outside the circular building.
The maintenance work is done rapidly and efficiently, because all subprocesses are in the same
warm building and near each other. The centralized control room improves the control of the mill.
Consumption of electric energy decreases as a result of shorter pipe lines, smaller amount of water
that need treatment, and the chosen equipment. Most of the blow off heat from the digester plant
is utilized at the evaporation plant; heat can thus be saved. More power is produced to the market
compared with a mill based on today's technology.
The model enables the treatment and control of ail emissions to the environment. Ducts for
collecting the emissions into the air are short. Thanks to thorough effluent treatment, continuous
digesting, oxygen bleaching, and well controlled process, the degree of coloration of the effluents,
AOX-emissions, and COD-emissions are lower than in a conventional solution.
5.2 Scale of Operation: The mill's design production capacity is 1500 t/d. The steel building's
diameter is 200 m and eave height 35 m.
5.3 Stage of Development: Preliminary study stage.
5.4 Level of Commercialization: See 5.3.
2-177
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Quantity After
100
100
100
N/A
N/A
100
100
55
70
45
N/A
N/A
90
90
204 kWh/Adt
5.5 Material/Energy Balances and Substitutions
Material Category Quantity Before
Waste Generation:
AOX
COD
Colour
Feedstock Use:
Water Use:
Energy Use:
Electricity
Steam
Extra power produced
6.0 Economics
6.1 Investment Costs: On the basis of received budgetary tenders and made calculations the studied
pulp mill is approximately 3 % cheaper than the reference mill.
6.2 Operational and Maintenance Costs: The need for operating personnel is according to calculations
about 210 persons, whereas the corresponding number in the reference mill is about 300.
6.3 Payback Time:
7.0 Cleaner Production Benefits
See 4.0.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study was Performed: This preliminary study will be published in 1992.
10.0 Contacts and Citation
10.1 Type of Source Material: An abstract provided by the contact person.
10.2 Citation:
10.3 Level of Detail of the Source Material: Additional information is not available in the source
material.
10.4 Industry/Program Contact and Address: Vesa Junttila, CTS Engineering Oy, P.O.Box 193, SF-
45101, Kouvola, Finland, phone: 951-2971, fax: 951-11684, telex: 52308 tsfin sf
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type: Pulp mill effluent.
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11.2 Process type/waste source: Chemical pulp mill, Sulphate pulp mill.
11.3 Cleaner Production Technique: Centralized layout, Control of environmental loads.
11.4 Other Keywords:
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chemical pulp mill, Sulphate pulp mill, Centralized layout, Control of environmental loads.
2-179
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***** DOCNO: 400-044-A-233 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Use of dry bark stripping process eliminates wastewater and generates
energy.
Pulp and Paper Industry/ISIC 3411
The USSR State Committee for Science and Technology
Wet barking in drums is substituted with dry wood barking which virtually
eliminates the generation of wastewater. Instead of adding water to the
barking drum, the dry bark stripping process uses steam to intensify the
bark stripping, producing only solid wood waste. The wet bark stripping
process supplies hot and cold water to the barking drums to intensify the
process. This process produces a water-borne waste and solid waste.
Wood material for the manufacture of pulp and paper products (pulpwood)
Solid waste, wood
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Dry barking provides significant cost savings not only because of the
exclusion of the treatment of wet bark and bark containing wastewater but
also because of the higher energy content of the dry bark. Bark-fired '
boilers can provide up to 20 per cent of a facility's steam requirements.
The combined method results in a substantial reduction of water
requirements compared to conventional wet barking.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Technological Process of Dry
Bark-Stripping of Wood in Barking Drums," Monograph
ENV/WP.2/5/Add.44.
Pulp and Paper, ISIC3411
2-180
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***** DOCNO: 400-006-A-197 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Pressurized grinding of processed wood, reduces energy consumption, and
improves paper properties.
Pulp and Paper Industry; Mechanical Pulping by Stone Grinding/ISIC 3411
Oy Tampella Ab, SF-33100 Tampere 10, Finland.
26 March 1979/Mr. Matti Aario, Product Engineering Manager of Stock
Preparation Department
The company changed the construction of the conventional hydraulic stone
grinder so that the processed wood is ground in a gas tight space under
pressure. Pressurized grinding has been implemented as a batch process.
The experiments were carried out with a production scale T 1512 grinder,
by altering the machine to perform under pressure. As a result of the trial
runs, mechanical pulp of a new type was obtained, the strengths of which
- especially the tearing resistance - were considerably better than those of
the stone-ground wood, corresponding to the strength figures of
thermomechanical pulp. Furthermore, it became evident that the energy
consumption needed by the process was lower than of the presently known
processes for manufacturing of mechanical pulp. The feeding of wood into
the grinder was done manually through a gate that can be lifted by a crane
so that during the feeding the pressure is released from the grinder.
Not reported
Not reported
Not reported
At the present development stage of the process investment requirements are
not available.
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Improved paper properties and reduced energy consumption.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Pressurized Stone Grinding for Mechanical
Pulp Production," Monograph ENVAVP.2/5/Add.6.
Pulp and Paper, ISIC 3411, Mechanical Stone Grinding
2-181
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The APCEL pulp mill development project would improve effluent quality.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company
Apcel Pty Ltd, Princes Highway, Snuggery, South Australia 5280, Australia.
4.0 Cleaner Technology Category
The Apcel pulp mill redevelopment project, by expansion in long-fibre softwood chemical pulping capacity
and by converting the existing chemical pulp mill to use Eucalyptus, both based on the magnesium bisulfite
process, called the Magnetite process and peroxide bleaching would improve effluent quality.
The project would significantly improve the quality of the plant's main drain effluent through the addition
of chemical recovery, peroxide bleaching and secondary effluent treatment facility. Biological oxygen
demand, adsorbable organohalogens, AOX, total suspended solids and colour would be reduced.
5.0 Case Study Summary
5.1 Process and Waste Information
The Magnefite pulping process was chosen for the Apcel redevelopment for the following reasons:
Sulfite pulp has an unbleached brightness of 55% compared with 30% for Kraft pulp. This
allows sulfite pulp to be bleached to a level acceptable to the market, without the use of
chlorine or chlorine compounds.
- The capital cost of an installed and operating Magnefite mill is approximately half to .two-thirds;
of that of a Kraft mill.
The Magnefite process allows recovery and recycling of the cooking chemicals.
The spent cooking liquor would pass through the following steps in the chemical recovery stage:
The liquor is concentrated by evaporation in several stages and combusted in a recovery boiler,
resulting in the formation of magnesium oxide and sulfur dioxide in the boiler flue gases.
Chemical recovery follows, where magnesium oxide would be recovered in a wet scrubber.
The magnesium oxide would then be passed to another scrubber through which the sulfur dioxi-
de-rich flue gases would pass, resulting in the formation of raw magnesium bisulfite liquor.
The raw liquor would be clarified and filtered for reuse.
The pulp would be bleached using the peroxide steep bleaching process.
The secondary treatment plant would consist of either aeration lagoons or activated sludge
treatment, or a combination of these two techniques.
Significant improvements in effluent quality would result from the proposed redevelopment.
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5.2 Scale of Operation: The expansion in soft-wood chemical pulping capacity would be achieved by
the construction of a new chemical pulp mill with a capacity of 250 ADt/d (90,000 ADt/a). The
existing chemical pulp mill would be converted to a 110 ADt/d (40,000 ADt/a) capacity Eucalyptus
mill.
5.3 Stage of Development: The technology has been fully implemented.
5.4 Level of Commercialization: The technology is commercially available.
5.5 Material/Energy Balances and Substitutions
Material Category
Waste Generation:
Quantity Before
BOD 188 kg/ADt
AOX 7.6 kg/ADt total
suspended solids
15.4 kg/ADt
colour 1 075 HU
N/A
35 ML/d
21 MW
Quantity After
7 kg/ADt
<0.1 kg/ADt
5 kg/ADt
<200HU
Feedstock Use: N/A N/A
Water Use: 35 ML/d 35 ML/d
Energy Use: 21 MW 27 MW
6.0 Economics
6.1 Investment Costs
•The project would result in a expenditure of $195 million (Australian dollars).
6.2 Operational and Maintenance Costs
6.3 Payback Time
7.0 Cleaner Production Benefits
By the proposed redevelopment of the Apcel operations, the company will meet the community expectations
for effluent discharges to the adjacent Lake Bonney. Applicable effluent standards will be met or bettered.
Odorous air emissions resulting from the pulp cooking process will be reduced. The use of chlorine or
chlorine compounds to bleach pulp will be eliminated. The acute and chronic toxicity of effluent will be
reduced. The solid waste disposal practices will be improved.
8.0 Technical Constraints
The existing chemical pulp mill would require comparatively few equipment changes to convert it to the
Magnefite process. These changes would include a new large dual use heat exchanger, an additional
washing stage, new primary and secondary knotter screens, pumps and pipework to transfer cooking liquor,
and fans and ductwork to transfer non-condensable gases to the new pulp mill recovery plant.
9.0 Date Case Study was Performed
The new pulp mill would be commissioned in the third quarter of 1992 and the existing chemical pulp mill
conversion in late 1992. The secondary effluent treatment plant is proposed to be installed in 1994.
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10.0
Contacts and Citation
10.1 Type of Source Material
Journal article and a draft environmental impact statement.
10.2 Citation
1.
2.
Trafford, J., A new look at a an old process - The application of peroxide steep bleaching to radiata
pine bisulfite and thermomechanical pulps, Appita, Vol. 43, No. 5, September 1990, pp. 358-366.
APCEL Pulp Mill Redevelopment Project, Draft Environmental Impact Statement, Prepared for
Apcel Pty Ltd by Kinhill Engineers Pty Ltd, June 1990, 17 p.
10.3 Level of Detail of the Source Material
Additional information on the laboratory tests, pulpwood resources and environmental impacts is
available.
10.4 Industry/Program Contact and Address
John Trafford, Environmental and Development Chemist, Kimberly-Clark Australia, Apcel Mill,
Millicent, South Australia, 5280.
10.5 Abstractor Name and Address
Mrs. Virve Tulenheimo, MSc, Research Engineer
Technical Research Centre of Finland
Non-Waste Technology Research Unit
P.O. Box 205
SF-02151 Espoo
Finland
Tel. +350 0 4561
Telefax +358 0 460 493
Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Chemical pulp mill effluent.
11.2 Process type/waste source: Bisulfite pulping, Pulp bleaching.
11.3 Cleaner Production Technique: Magnesium bisulfite pulping, Peroxide steep bleaching.
11.4 Other Keywords: Eucalyptus.
11.5 Country Code: Australia.
12.0 Assumptions
13.0 Peer Review
Yes (No 1 in 10.2) and known (No. 2 in 10.2).
2-184
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
.KEYWORDS: Chemical pulp mill effluent, Bisulfite pulping, Pulp bleaching, Magnesium bisulfite pulping.
Peroxide steep bleaching, Eucalyptus.
2-185
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Milox organosolv pulping process offers a workable alternative to sulphate cooking and
does not need any chlorine bleach chemicals.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
The Finnish Pulp and Paper Research Institute, P.O.Box 70, SF-02151 Espoo, Finland.
4.0 Cleaner Technology Category
The Milox process is a sulphur-free peroxyformic acid pulping method, which was the first process to
produce fully bleached chemical pulp both from hardwood and softwood totally without sulphur and
chlorine chemicals.
Milox method can also be used to prebleach conventional kraft pulps. The prebleaching makes it possible
to reach high brightness in a subsequent final bleaching entirely without chlorine chemicals.
5.0 Case Study Summary
5.1 Process and Waste Information: Peroxyformic acid has the ability selectively to delignify wood.
The lignin is oxidized and broken down, and together with extractives and hemicelluloses, dissolves
in the pulping liquor. The sulphur-free lignin can be precipitated from the spent liquor.
A-three-stage cooking process allows peroxide consumption to be reduced. The first stage involves
acid cooking in the presence of small amounts of peroxide at 80°C; this is followed by refluxing
in formic acid without peroxide, at 100°C. The process ends with oxidative peroxyformic acid
cooking, again at 80°C.
This method converts both birch and pine into pulps with well separated fibres in yields of 40-50%
depending on the Kappa number. Some pulping experiments have been made with Eucalyptus
Globulus. The viscosity of the pulp is high, indicating little chemical damage to the cellulose.
At the end of the cooking process, birch pulp reaches a brightness of 47 %, while pine pulp achieves
35%, with Kappa numbers of 3.5 and 9.0 respectively. Both birch and pine peroxyacid pulps can
be bleached to over 90 brightness by means of an alkaline hydrogen peroxide.
Viscosity remains high and the low lignin content of the fibres keep peroxide consumption down.
The strength properties of Milox birch pulps are close to those of birch kraft pulp. However the
strength characteristics of pine peroxyacid pulps are much poorer than those of the corresponding
sulphate pulps.
The kraft pulps prebleached with peroxyformic acid reach a brightness of 86% with alkaline
hydrogen peroxide only. In a final stage using oxygen, ozone and peroxide, kraft can be bleached
to 90 brightness.
Both birch and pine Milox bleached kraft pulps show strength characteristics and optical properties
similar to those of conventional kraft pulps.
Pulps produced using the Milox method and kraft pulps bleached with chlorine-free Milox method
are all compatible with grades where kraft pulp is used today. Hardwoods can also be made into
dissolving pulp.
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5.2 Scale of Operation: Laboratory scale. A pilot plant, which comprises in the first phase a cooking
and bleaching unit to produce around 100 kg of pulp at a time, started up in autumn 1991. Formic
acid recovery and recycling systems will be added in 1993.
5.3 Stage of Development: Laboratory stage, moved to pilot stage.
5.4 Level of Commercialization: Provided the results are positive, planning of a full scale mill could
be envisaged after five years.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
•N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
6.0 Economics*
6.1 Investment Costs: The cost of the first phase (cooking and bleaching) pilot will be around FMK
10 Mill. If the second phase is built the figure will be around doubled.
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
So far the effluents have not been characterized. The recovery systems of the pilot plant should provide
important data. The greatest advantage is, however, that the effluent contains no chlorinated organic
compounds.
8.0 Obstacles, Problems and/or Known Constraints
Use for the precipitated lignin has not yet been found.
9.0 Date Case Study Was Performed: Work on the process was begun in 1985. The pilot plant was ready in
autumn 1991.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and a book.
10.2 Citation:
(1) Pride, D., Chemical pulping and bleaching - Old pulps for new, Paper, 6 November, 1990, pp. 26-28;
(2) Pulping technology - Beyond the kraft process, Asia Pacific Pulp & Paper, May 1991, pp. 15-17;
(3) Poppius, K., Sundquist, J. and Wartiovaara, I., Chemical pulping of birch and pine chips by the three
stage peroxyformic acid method, in Wood Processing and Utilization, John Wiley & Sons, pp. 87-92.
2-187
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10.3 Level of Detail of the Source Material: Information on pulp properties is available in the source
material.
10.4 Industry/Program Contact and Address: K. Poppius-Levlin, The Finnish Pulp and Paper Research
Institute, P.O.Box 70, SF-02151 Espoo, Finland.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulping effluent, Bleaching effluent
11.2 Process type/waste source: Chemical pulping
11.3 Cleaner Production Technique: Organosolv pulping, Milox-process, Peroxyformic acid method,
Chlorine and sulphur-free pulping
11.4 Other Keywords: Hydrogen peroxide, Formic acid, Bleaching
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulping effluent, Bleaching effluent, Chemical pulping, Organosolv pulping, Milox-process,
Peroxyformic acid method, Chlorine and sulphur-free pulping, Hydrogen peroxide, Formic acid, Bleaching
2-188
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*****DOCNO: 400-088-A-317*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Addition of oxygen bleaching reduces quantities of reagents and water used
and coloration of wastes.
Manufacture of Pulp, Paper and Paperboard/ISIC 3411
This case study presents a modification to the bleaching stage of pulp
manufacturing. Bleached kraft pulp is manufactured by cooking, washing,
and bleaching wood chips. Modification of the standard bleaching process
by preceding the chlorine, caustic soda, and chlorine dioxide bleaching with
oxygen bleaching will reduce the quantities of reagents and water used in
the conventional bleaching process. Washing water resulting from oxygen
bleaching may be used for washing the pulp after cooking. This process
reduces the coloration of wastes.
Material requirements for low-pollution manufacturing one ton of pulp: 4
tons of wood, 50m3 of water, 25 kg of caustic soda, 45 kg of chlorine, 10
kg of chlorine dioxide, 30 kg of oxygen, 8.78 GJ of primary energy.
Polluting wastes consist of bleaching effluents.
Aqueous
FF 24,000,000 (1973 figures) for an annual production of 170,000 tons of
pulp
FF 13.3 per ton of pulp (1973 figures) '
FF 9.1 per ton of pulp in raw chemicals cost and water consumption
The following reductions in feedstocks have been reported per ton of pulp
manufactured: 50 m3 of water, 10 kg of caustic soda, 55 kg of chlorine,
5 kg of chlorine dioxide.
Polluting wastes by the bleaching process consist of the bleaching effluents.
Switching from the standard to the low pollution technique permits reducing
by half the rate of coloration of wastes.
Additional variable expenses of energy and manpower (F 13.3 per ton) are
partly offset by savings in chemicals and water (F 9.1).
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Paper/board Making with Closed Water
Systems," Monograph ENV/WP.2/5/Add.88
Paper, Pulp, Bleaching, Kraft Paper, ISIC 3411
2-189
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DOCNO: 450-003-A-361*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Eddy Forest modernizes plant, improves pulp quality and reduces discharges
and emissions of particulates and sulfur gases.
Paper and Allied Products/SIC 26
Eddy Forest Products, Ltd.
Espanola, Ontario
This pulp mill pioneered commercial oxygen bleaching of softwood kraft
pulp in 1977 by using the Modo-cil-oxygen/alkali bleaching process and
reducing chlorine consumption by over 50%. A modernization project has
increased capacity of the chip handling, digester, bleach plant, recovery
boiler and evaporator. A new black-liquor evaporation system that can
produce black liquor up to 75% solids and a new low-odor recovery boiler
have been installed. Foul condensates from the digester and evaporator are
steamstripped to remove sulfur gases and methanol, which are incinerated..
A new bleaching line consists of two 3-stage lines which are each preceded
by an oxygen and hot chlorination stage. Effluent is recycled through the
system.
Wood chips, chlorine, fuel
Emissions, methanol, BOD wastes
Air, liquid, solids
Not reported
Not reported
Not reported
Not reported
Dollar values not reported.
Oxygen bleaching has reduced chlorine consumption by over 50% and
bleaching costs by 10-15%.
Oxygen bleaching has reduced effluent BOD by 50%. A new secondary
water-treatment system has decreased BOD levels by 80-95%. The recovery
boiler system has reduced emissions by 88% for particulates, and 99% for
sulfur gases.
Plant Modifications have enabled the company to meet government water
pollution regulations, have increased bleaching capacity to 1000 tons/day,
and have improved product quality..
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 63.
Pulp and Paper, Bleached Kraft Pulp, Sulfur, Chlorine, Recycling, Process
Change, SIC 26
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***** DOCNO: 452-003-A-001 *****
1.0 Headline: Advanced pulp bleaching technology and mill design reduce adsorbable organic halogen (AOX)
levels
2.0 SIC Code: 2611
3.0 Name & Location of Company
Wisaforest, Jakobstad
Pietarsaari, Finland
4.0 Clean Technology Category: The technology involves advanced pulp bleaching technology using oxygen
bleaching, washing, and screening to reduce AOX levels.
5.0 Case Study Summary
5.1 Process and Waste Information: The company produces bleached and unbleached pulp, mostly
from hardwood, with some eucalyptus from South America. The clean technology involves use of
the Sunds Defibrator pulp technology in the bleaching, washer, and screening plant. The five-stage
bleaching plant has a D/D-OE-D-E-D sequence. The oxygen bleaching technology and effluent
controls reduce AOX levels below regulatory levels.
5.2 Scale of Operation: The facility produces 540,000 tpy of bleached and unbleached pulp.
5.3 Stage of Development: The technology is fully developed.
5.4 Level of Commercialization: The facility uses the Sunds Defibrator pulp technology.
5.5 Material/Energy Balances and Substitutions: No information provided.
6.0 Economics*
6.1 Investment Costs: No information provided.
6.2 Operational & Maintenance Costs: No information provided.
6.3 Payback Time: No information provided.
7.0 Cleaner Production Benefits: AOX levels are reduced below regulatory levels.
8.0 Obstacles, Problems, and/or Known Constraints: No information provided.
9.0 Date Case Study Was Performed: Information not provided.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article
10.2 Citation: Pride, D. Old pulps for new. Paper, 6 November, 1990. p. 28.
10.3 Level of Detail of the Source Material: A brief description of the companies other subsidiaries is
provided, docu
2-191
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10.4 Industry/Program Contact and Address: The technology is produced by Sunds Defibrator. Martin
Granhold of Wisaforest is the facility contact.
10.5 Abstractor Name and Address: Barbara M. Scharman, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: AOX effluents
11.2 Process type/waste source: Pulp mills, bleaching
11.3 Waste reduction technique: Oxygen bleaching, effluent controls
11.4 Other keywords: Finland
(*)-
Keywords:
Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Bleaching, Process Modification, Pulp Mills
2-192
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***** DOCNO: 452-003-A-001 *****
1.0 Headline: Chlorine and sulphur-free pulp process planned for pilot plant project
2.0 SIC Code: 2611
3.0 Name & Location of Company
Finland
4.0 Clean Technology Category: The technology involves a cooking process for hard and soft woods using
peroxyformic acid and a bleaching process using alkaline peroxide to produce a chlorine and sulphur-free
pulp.
5.0 Case Study Summary
5.1 Process and Waste Information: Sulphate cooking and bleaching of pulp have traditionally been
used in pulping mills. An alternative technology, the Milox process, involves cooking the wood
using a three-stage process. The first stage involves acid cooking at 80 degrees C in the presence
of small amounts of peroxide. The second stage involves refluxing with formic acid at 100 degrees
C. The final stage consists of cooking at 80 degrees C with peroxyformic acid. The peroxyformic
acid selectively delignifies wood and the lignin can be recovered from the spent liquor. The
cooking is accelerated using this process and peroxide consumption is minimized. The resulting pulp
from the cooking process can be bleached with alkaline hydrogen peroxide to a brightness over 90%
for birch and pine. Kraft pulps reach a brightness of 86 % and can be treated with oxygen, ozone,
and peroxide to achieve 90% brightness.
The new technology converts both birch and pine into pulps with well separated fibers in yields of
40-50 %, depending on the Kappa number. Experiments have also been conducted with Eucalyptus
Globulus. Little chemical damage to the cellulose occurs, as indicated by the high viscosity of the
pulp. The strength characteristics of pine peroxyacid pulps are inferior to those of pine sulphate
pulps. The potential effluents from the process have not yet been characterized but the recovery
system in the pilot plant may provide some information. However, no chlorinated organic
compounds should be present.
5.2 Scale of Operation: The pilot project's first phase will consist of a unit with a capacity of about
100kg.
5.3 Stage of Development: Experimental studies have been conducted. The first phase of the pilot
plant project is scheduled for fall, 1991. If successful, formic acid recovery and recycling systems
will be added in 1992.
5.4 Level of Commercialization: A full-scale mill could be planned after five years, if results of the
pilot plant are positive.
5.5 Material/Energy Balances and Substitutions: No quantitative data were provided concerning raw
materials usage or waste generation.
6.0 Economics*
6.1 Investment Costs: The cost of the first phase will be about 10M (FM). If the second phase is
added, consisting of the recovery and recycling systems, the cost will be another 10M.
2-193
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6.2 Operational & Maintenance Costs: No information provided.
6.3 Payback Time: No information provided.
7.0 Cleaner Production Benefits: The new technology will produce a chlorine and sulphur-free pulp. No
chlorinated organic compounds will be present in the effluent. Peroxide use is minimized and lignin can
be recovered from the spent liquor although a use for it has not been found.
8.0 Obstacles, Problems, and/or Known Constraints: Strength characteristics of pine peroxyacid pulps are
inferior to those of pine sulphate pulps.
9.0 Date Case Study Was Performed: Information not provided.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article
10.2 Citation: Pride, D. Old pulps for new. Paper, 6 November 1990. p. 26.
10.3 Level of Detail of the Source Material: The article briefly discusses another pilot plant involved
in chlorine-free high whiteness pulping.
10.4 Industry/Program Contact and Address: The technology was developed by Professor Jorma
Sundquist at the Finnish Pulp and Paper Research Institute.
10.5 Abstractor Name and Address: Barbara M. Scharman, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: Chlorinated organics
11.2 Process type/waste source: Pulp mills
11.3 Waste reduction technique: Process modification, material substitution, material conservation,
Milox process
11.4 Other keywords: Chlorine reduction, sulphur reduction, Finland
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chlorinated Organics, Material Substitution, Material Conservation, Milox Process, Process
Modification, Pulp Mills, Chlorine Reduction, Sulphur Reduction, Finland
2-194
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Use of a Drum Displacer (a multistage pulp washer) allows all the washing stages to be carried
out in a single drum.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Enso-Gutzeit Corporation's Kotka mill and Kymmene Corp., at the Kaukas mill, both in Finland.
4.0 Cleaner Technology Category
The pumping energy and the washing water quantity are reduced.
5.0 Case Study Summary
5.1 Process and Waste Information: The Drum Displacer is a new multistage washer where all washing
stages are carried out with one drum. The washer consists of a rotating drum with sectors and of
a housing around the drum. Further, the housing has been divided into various zones. One of the
main components is the distribution valve.
Pulp is pumped at a consistency of 4-6 % to the feed zone, where it is thickened approximately up
to 10%. Pulp is washed at this consistency, but is not diluted nor thickened during washing. In the
thickening zone, the pulp is dewatered by means of vacuum. Then the consistency rises
approximately up to 15%. The pulp is discharged by compressed air.
The washing is carried out as a four stage displacement washing on the counter-current principle.
The washing liquid is pumped to the fourth washing zone, from where the liquid passes through
the pulp to the third washing zone. This is repeated in the second and first washing zones. The
filtrate from the first zone flows to the filtrate tank.
5.2 Scale of Operation: The Enso-Gutzeit's washer capacity is 80 ADMTPD (air dry metric ton per
day) and the Kymmene's 200 ADMTPD. The raw material in both mills is saw dust of birch and
pine.
5.3 Stage of Development: The Drum Displacer pulp washer is fully implemented.
5.4 Level of Commercialization: The process discussed is commercially available. The washing
machinery is specially designed for this application.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
100
100
100
100
Quantity After
reduced (see water)
100
80
50
6.0
Economics*
6.1 Investment Costs:
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6.2 Operational and Maintenance Costs: The single unit process reduces the maintenance requirement
to a minimum. The average maintenance time the washer has required is 8 hours/year.
6.3 Payback Time: The reduced number of equipment (25 vs. 100) enables installation in a smaller
space. Pulp is not diluted between different washing stages. The quantity of liquid to be pumped
and the energy needed for pumping decrease considerably. Pulp washing is carried out in a
pressurized liquid phase resulting in more complete displacement. Pulp can be washed clean with
a smaller water quantity. During washing the quantity of circulating wash liquid is small and the
retention time short (3 min) compared to the filter washing line (more than 600 min). The washing
is controlled almost without retention time.
7.0 Cleaner Production Benefits
The reduced number of equipment (25 vs. 100) enables installation in a smaller space. Pulp is not diluted
between different washing stages. The quantity of liquid to be pumped and the energy needed for pumping
decrease considerably. Pulp washing is carried out in a pressurized liquid phase resulting in more complete
displacement. Pulp can be washed clean with a smaller water quantity. During washing the quantity of
circulating wash liquid is small and the retention time short (3 min) compared to the filter washing line
(more than 600 min). The washing is controlled almost without retention time.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: The mill scale installations where reported in 1987.
10.0 Contacts and Citation
Journal, a report of technologies from Finland and Conference
10.1 Type of Source Material:
proceedings.
10.2 Citation: (1) Advances is Pulping, Tappi Journal, November 1988, pp. 16-20; (2) Environmental
High-Technology from Finland, prepared by Mexpert Consulting Engineers Ltd. for the Ministry
of the Environment, Helsinki 1987, pp.23-24; (3) Perkola, M., Sundquist, H., Pikka, O., Qvintus,
H. and Sainiemi, J., Drum Displacer - A new concept for brown stock washing, Tappi
Proceedings, Pulping Conference, 1988, pp. 117-122.
10.3 Level of Detail of the Source Material: Additional information on the operating principle of the
DD washer is available in the source material.
10.4 Industry/Program Contact and Address: Mrs Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205,
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf
10.5 Abstractor Name and Address: Same as in 10.4.
11.0 Keywords
11.1 Waste type: Pulping waste water
11.2 Process type/waste source: Washing, Pulp washing, Brownstock washing
11.3 Cleaner Production Technique: Multistage pulp washer, Drum Displacer, Displacement washing
11.4 Other Keywords:
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11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulping waste water, Washing, Pulp washing, Brownstock washing, Multistage pulp washer, Drum
Displacer, Displacement washing
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DOCNO: DOCUMENT NOT AVAILABLE *****
1 .0 Headline: Pressurized groundwood (PGW) and super pressurized groundwood (PG W-S) processes produce
pulps of almost same strength properties as TMP (thennomechanical) pulps using less energy.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
There are almost twenty mills all over the world using the PGW technology in grinding and the following
two using the PGW-S technology:
Kymmene Corporation, Kaukas Voikkaa Division, Voikkaa Paper Mill, Voikkaa, Finland.
Myllykoski Oy, Myllykoski MiU, Myllykoski, Finland.
4.0 Cleaner Technology Category
The mechanical pulp strength properties can be developed by the PGW process without more energy. The
PGW-S process requires significantly less energy to achieve strength comparable to TMP. The PGW-S
improves the properties compared to PGW.
5.0 Case Study Summary
5. 1 Process and Waste Information: The groundwood pulp flows out of the pressurized grinder through
a shredder, discharged through a blow valve into a blow cyclone, and then into a filter. From the
filter the hot filtrate returns to a shower water tank and the discharge pulp is re-diluted to a
controlled consistency ahead of screening.
In the PGW and PGW-S processes the grinder has been built to be pressure proof. The grinder can
be pressurized by using air, thus the grinding temperature can be raised. Due to the higher
temperature and pressure the lignin is softened in the grinding, resulting in stronger and more fibril-
lated pulp.
The effect of the shower water temperature on groundwood pulp properties was compared in the
tests. Shower water temperatures ranged up to 140°C and grinder overpressure up to 450 kPa.
From the results it can be confirmed that mechanical pulp strength properties can be developed
without more energy. The use of superheated shower waters and higher overpressures improves the
strength properties of super pressure groundwood by 15 to 20% compared to conventional PGW.
5.2 Scale of Operation: The technology has been implemented in full scale mechanical pulp mills.
' 5.3 Stage of Development: Fully implemented. First commercial PGW plant was started in the summer
1980, and the first PGW-S plant in 1991. The method has been patented in the countries most
important from the point of view of paper production.
5.4 Level of Commercialization: There are pressure grinders operating all over the world.
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5.5 Material/Energy Balances and Substitutions:
Material Category
Quantity Before
(TMP)
Quantity After
(PGW-S)
15-25 kg/t paper
N/A
N/A
1.7-1.9MWh/t
95%
12-17 kg/t paper
N/A
N/A
1.1-1.3 MWh/t
4.2 GJ/t
97%
Waste Generation:
BOD7
Feedstock Use:
Water Use:
Energy Use:
electricity
steam
Pulp yield:
6.0 Economics*
6.1 Investment Costs: The costs will be calculated case by case.
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 . Cleaner Production Benefits
The main goals of the research and development work have been to produce fiber that better meets the
market need, to lower the consumption of energy, and to keep the consumption of more and more limited
wood material as low as possible.
Due to better properties of pressure groundwood pulps, the share of chemical pulp in paper production
could have been decreased from 20% to 10%.
8.0 Obstacles, Problems and/or Known Constraints
Spruce, different pine species and populus are the best raw materials for PGW and PGW-S processes.
Hardwood can't be used. Some exotic hardwoods can be tested in the pilot plant.
9.0 Date Case Study Was Performed: Since the year 1976 Tampella Ltd (Finland) has made research work
for the possibilities to improve the properties of groundwood. Preliminary trials were made in the year,
1977 and a full-sized prototype construction was started in 1979. The first commercial PGW plant started
in 1980 and the first PGW-S plant in 1991.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles, conference proceedings and brochures.
10.2 Citation:
(1) Mitchell, G. and Tapio, M., PGW/CPGW Mills Report Low Effluent Loads, Reduced Steam
Contamination, Pulp & Paper, June 1990;
(2) Pulping: Kymmene puts pressure on, PPI, February 1992, p. 50 and p. 57;
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11.0
12.0
13.0
(*)-
(3) Beaudry, R.N., Towards a Zero Effluent PGW Pulp Mill, 77th Annual Meeting, Technical Section,
Canadian Pulp & Paper Association, January 1991, Montreal, Canada, pp. B339-B340;
(4) Pasanen, K., Peltonen, E., Haikkala, P. and Liimatainen, H., Experiences in using super pressure
groundwood (PGW-S) in Myllykoski SC-paper mill, Proceedings, International Mechanical Pulping
Conference, June 1991, Minneapolis, USA, 8 p.;
(5) Haikkala, P., Liimatainen, H., Manner, H. and Tuominen, R., Pressure groundwood (PGW), super
pressure groundwood (PGW-S) and thermomechanical pulp (TMP) in wood-containing printing papers,
Preprints, International Mechanical Pulping Conference, Helsinki, June 1989, Volume 1, 13 p.;
(6) Pressure groundwood mechanical pulp, Tampella papertech, brochure;
(7) Pressure groundwood process, Tampella, Pulping and paper machinery group, Brochure.
10.3 Level of Detail of the Source Material: Fiber balances in TMP, GW and PGW processes, process
conditions and pulp properties are available in the source material.
10.4 Industry/Program Contact and Address: Tampella Papertech Oy, Mechanical Pulping Machines,
P.O.Box 606, SF-33101 Tampere, Finland, tel.+358-31-24 12 111, telex 22650 tamas sf, fax
+358-31-149 810
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
Keywords
11.1 Waste type: Pulp mill effluent
11.2 Process type/waste source: Mechanical pulping, High-yield pulping, Pressure groundwood. Super
pressure groundwood, Thermomechanical pulp, Paper production
11.3 Cleaner Production Technique: Energy saving
11.4 Other Keywords:
11.5 Country Code: Finland.
Assumptions
Peer Review
Yes (No 1 and 2 in 10.2) and unknown (No 3-7).
Disclaimer Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp mill effluent, Mechanical pulping, High-yield pulping, Pressure groundwood, Super pressure
groundwood, Thermomechanical pulp, Paper production, Energy saving
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
Headline: Treatment of pine wood chips with recyclable commercial ethanol
(96oGL) as a pre-treatment for the thermomechanical pulping process (TMP) allows possible separation
of toxic wood extractives.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Institute de Pesquisas Technologicas do Estado de Sao Paulo S. A. - IPT, DPFTC - Agrupamento Celulose
ePapel, P.O.Box 7141,01064-970-SaoPauloSP-Brasil, phone: 55 11 2682211, fax- 55 11 8693353 telex-
11 83144 INPTBR.
4.0 Cleaner Technology Category
Process modification with solvent and extractives recovery.
5.0 Case Study Summary
5.1 Process and Waste Information: Process Area: Thermomechanical pulp plant.
Base Process: In the thermomechanical pulping process (TMP), the wood chips are washed, receive
a steam treatment at atmospheric pressure, and are then compressed by a screw press that feeds
them into a pressurized vessel where a steam treatment (pre-steaming) is applied. The wood chips
are transformed into a pulp when they are forced, between the two disks of a pressurized refiner.
This is the first step of the TMP process. The pulp produced undergoes one or two further refining
operations carried out under atmospheric pressure. This is the second step of the TMP process.
Process Changes: Inclusion of two operations in the original TMP process: first, the impregnation
of wood chips with commercial ethanol. Second, the evaporation of the ethanol extract and
recovery of the solvent.
Effect of Wastes: In the base TMP process, wood chips are screw-pressed and yield a toxic
component rich waste concentrate that has to be treated. In the alternative process, effluents are
evaporated, the solvent is recycled, and the wood extractives are separated and can be burned.
Raw materials: Pinus elliottii var. elliottii is the main raw material, reduced to wood chips.
Commercial ethanol is necessary to start the process.
Energy Usage: As the wood chips are softened, there is a reduction of energy consumption in the
first and second steps of the base TMP process. The recovery operations may effect the final
energy balance.
Operating Procedures: In this alternative process, the ethanol extract obtained in the normal TMP
process is collected in a storage tank. The liquor is pressurized with a pump and flashed into a tank
heated up with the steam generated in the first step of the TMP process.
5.2
Scale of Operation: Full-scale TMP mills have a pulp output of 50-400 ADMT/day. The present
alternative process is still hi the experimental stage.
5.3 Stage of Development: Bench scale.
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5.4 Level of Commercialization: The technology is not yet ready for commercialization, but the
equipment used in the suggested alternative are available in commercial scale. .
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
6.0 Economics*
6.1 Investment Costs: Large-scale economic figures are not available. A rough technical and economic
evaluation of the suggested modification of the regular TMP process is presented in the literature
cited.
6.2 Operational and Maintenance Costs: Rough information about operational costs is presented in the
mentioned literature.
6.3 Payback Time: Not available.
7.0 Cleaner Production Benefits
This alternative offers a possibility of an easy separation of part of the wood extractives that are very toxic.
8.0 Obstacles, Problems and/or Known Constraints
The need to work with a. solvent (ethanol).
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Personal contact, conference proceedings, research work notes, academic
thesis.
10.2 Citation: 1. Neves, J.M., Impregnacao de cavacos de Pinus elliottii var. elliottii com alcool etilico
a 96oGL como pre-tratamento na producap de pastas tennomecanicas. Tese. EPUSP/Depto
Engenharia Quimica, Sao Paulo, 1984.
2. Neves, J.M. e Rossi, H., Pre-tratamento de cavacos de Pinus elliottii com alcool etilico no
processo termomecanico, in: Congr. Anual de Celulose e Papel, 19, ABCP, Sao Paulo, 1986, p.
161-176.
10.3 Level of Detail of the Source Material: Fairly well detailed.
10.4 Industry/Program Contact and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas
Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel,
P.O.Box 7141, 01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex:
11 83144 INPTBR.
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10.5 Abstractor Name and Address: Dr. Jose Mangolini Neves, institute de Pesquisas Technologicas
do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel, P.O.Box 7141,
01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex: 11 831441NPT
BR.
11.0 Keywords
11.1 Waste type: Wood extractives
11.2 Process type/waste source: TMP process, pulp production
11.3 Cleaner Production Technique: TMP process, pulp production
11.4 Other Keywords:
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wood extractives, TMP process, pulp production
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: A chemithennomechanical pulping pilot based on bivis extruder produces pulp for paper and
board trials with equipment adapted to use a new bleaching process.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Centre Technique du Papier, Domaine Universitaire, BP 7110, 38020 GRENOBLE cedex, France.
The pilot is located at the Lancey Mill, Aussedat Rey Group, close to Grenoble.
4.0 Cleaner Technology Category
The main feature of this process is pulp or chips sulfonation in reducing medium followed by H2O2
bleaching giving pulps at high level of brightness with good mechanical, properties. It seems possible to
replace all of the hardwoods chemical pulp and partly the softwood chemical pulp in coated base paper by
the bivis pulp without modification of the paper quality.
5.0 Case Study Summary
5.1 Process and Waste Information: This bivis process, called SRP process (sulfite reducing peroxyde),
is characterized by the following sequence:
• Pretreatment of chips with a chelating agent and washing.
• Impregnation with a sodium sulfite solution containing a more electronegative reducing agent
than the sulfite ions. Afterwards heating hi the absence of air at a temperature above 100°C
during 3 to 30 minutes.
• Washing and bleaching of the sulfonated pulp with hydrogen peroxide in alkaline medium.
The second step is the key point of the process; the impregnation must be carried out at .ambient
temperature in the absence of air. The reducing agent is added to the sulfonation liquor just before
the impregnation. The most efficient agent is sodium borohydrite used in the form of alkaline
solution containing 12% of sodium borohydrite and 40% of caustic soda. The molar ratio
Na'SCP/NaBH4 should be higher than 8.
The pilot unit is running continuously producing pulp lots for paper and board trials. It includes
principally two bivis machines and a double discs refiner operating in series. Chips defiberizing
and sulfonation in reducing medium is carried out in the first machine, washing and bleaching in
the second bivis machine. The bleaching reaction is carried out in a storage chest during one hour
at 90°C. Then the bleached pulp is refined, screened and dewatered on the wet lap machine ready
for use on a paper machine.
The installation also includes equipment for white waters recovery and their recycling in the process
and for the preparation of chemicals mixtures for sulfonation and bleaching.
Bleached bivis pulps have been manufactured from softwoods chips (mixture of fir, spruce, sawmill
waste) and from hardwoods (poplar).
5.2 Scale • of Operation: The capacity of the bivis pilot unit is 10 t/day of bleached
chemithennomechanical pulps.
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5.3 Stage of Development: The Lancey bivis pilot plant has been running continuously. The figures
are based on actual production.
5.4 Level of Commercialization: The process is patented and it needs special machinery (twin-screw
extruders, which can be considered as a high temperature - short time reactor).
This machinery is built and sold by Clextral Company, Z.I.de Chazeau BP 10, 42702 FIRMINY,
France, tel: 77 40 31 31, fax: 77 40 31 23.
5.5
Material/Energy Balances and Substitutions: See 6.2.
Material Category Quantity Before
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
6-7 m3/t of pulp
1700-1800 kWh/T of pulp (softwoods)
1600-1700 kWh/T of pulp (hardwoods)
6.0 Economics*
6.1 Investment Costs: Total investment for a CTMP green field mill based on BIVIS technology:
• pulp capacity: 50 t/d (cotton); 20 million US$, (machinery: 6.5 million US$)
• pulp capacity: 75 t/d (wood): 23,5 million US$, (machinery: 7.5 million US$)
6.2 Operational and Maintenance Costs:
• wood consumption: 1.76 t of wood/t of pulp AD (process yield: 92%)
• cotton consumption: 1.38 t of cotton/t of pulp AD (process yield: 87%)
• kWh: 1,700-1,800 kWh/t (softwood), 1,600-1,700 kWh/t (hardwood)
• chemicals:
- sodium hydroxide: 40 kg/t of pulp AD
- sodium sulfite: 40 kg/t of pulp AD
- hydrogen peroxide: 30-40 kg/t of pulp AD.
• maintenance costs
- operating supplies: 8 US$/t of pulp AD
- maintenance costs: 4% of investment cost/year.
6.3 Payback Time:
7.0 Cleaner Production Benefits
The Centre Technique du Papier (Grenoble) has been studying this new bleached high yield pulping process
with reduced energy consumption for several years. The equipment is well adapted to use the new
bleaching process developed by Atochem (chemical group) for the manufacture of softwoods and
hardwoods pulps. The bleaching is carried out with hydrogen peroxide. Both brightness of the unbleached
CTMP pulp and the hydrogen peroxide response to bleaching are greatly improved. Furthermore, it is
possible to produce very strong pulps at high brightness levels because the brightening ability of sodium
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borohydrite allows the use of higher levels of caustic in the sulfite treatment. Chemicals could be saved
when very high brightness is required.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article and conference proceedings.
10.2 Citation:
(1) de Choudens, C., Angelier, R., Devic, M. and Kervennal, J., Chemithermomechanical pulps at high
level of brightness obtained by the bivis process associated with a sulfonation in reducing medium, Paperi
ja Puu - Paper and Timber.72 (1990):3, pp. 248-252;
(2) Devic, M., Kervennal, J. and Lachapelle, R.C., CTMP - Improved brightness and strength by sul-
fonation in presence of a reducing agent, Tappi Proceedings, 1988 Pulping Conference, New Orleans,
Oct.30 - Nov. 2, Book 2, pp. 491-495.
10.3 Level of Detail of the Source Material: Additional information on bivis pulp and coating base paper
properties is available in the source material.
10.4 Industry/Program Contact and Address: C. de Choudens and R. Angelier, Centre Technique de
I'lndustrie des Papiers, Cartons et Celluloses, B.P. 7110, 38020 Grenoble, France
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: Chemithermomechanical pulp, brightness, sulfonation
11.3 Cleaner Production Technique: Bivis extruder
11.4 Other Keywords:
11.5 Country Code: France.
12.0 ' Assumptions
Peer Review
13.0
Yes (articles in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other-
factors.
Keywords: Chemithermomechanical pulp, brightness, sulfonation, Bivis extruder
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Neutral Sulfite-Anthraquinone (NS-AQ) pulping process offers advantages over kraft
pulping.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The United Paper Mills, Ltd., Rauma pulp mill, Finland.
4.0 Cleaner Technology Category
The NS-AQ pulping process results in higher yields and unbleached brightness levels than kraft pulping.
NS-AQ pulps consume less active chlorine in bleaching than kraft pulps.
5.0 Case Study Summary
5.1 Process and Waste Information: Pine and birch chips were screened and the fraction of 2-6 mm
thickness was used for pulping. The chips were pulped in a forced-circulation digester or in an
electrically heated rotating group digester with autoclaves. The pulping liquor for the NS-AQ cooks
was prepared for first absorbing SO2 into a NaOH solution until the pH was 11.2, after which
sodium carbonate was added as a buffer.
The NS-AQ cooks were performed under the following conditions: total alkali was 19-24% (as
NaOH); the AQ dose was 0.1-0.2% of owen dry wood; the alkali ratio (Na^O3:total alkali) was
0.6-0.94; the liquor-to-wood ratio was 3.5-4; the time to maximum temperature was 90-180 min;
and the time at 165-185°C was 20-240 min.
In all cooks anthraquinone was mixed into the cooking liquor before adding it to the digester.
The progress of delignification was followed in NS cooks under the following conditions: the liquor-
to-wood ratio was 4.5; total alkali was 24% (as NaOH); the AQ charge was 0.2%; time to
maximum temperature was 95 min; and time at 175 °C was 280 min. The cooks were interrupted
at different stages of pulping for total yield, carbohydrate, lignin, and similar determinations.
After pulping the pulps were washed in the digester or in a diffuser with warm water. High-kappa-
number pulps were defibered in a refiner.
Reference pine kraft pulps were also prepared.
The bleachability of pine and birch NS-AQ pulps was studied with the following bleaching
sequences: CEDH.CE/ODH, DE/ODH, OCEDH, ODE/ODH. In the C-stage no ClO2-addition was
used. The reference kraft pulps were bleached using the conventional sequence (C + D)EDED,
where CF-addition in C-stage was 15 % of active chlorine.
The trials resulted in chemically defibered pulps with high yields (55-64% on wood) and a
brightness of 45-55% ISO, the kappa number being 40-50. The optimum S:Na2 ratio was 0.80-
0.85. The pulps were fairly easy to bleach with the above mentioned sequences. The bleached
yield of pine pulp was 49-51 % and that of birch pulp 53-55 %. The papermaking properties of the
NS-AQ pulps were quite equal to those of kraft pulps except for the lower tear strength. The NS-
AQ pulps are suitable for reinforcement pulp in newsprint, certain kraft papers, offset paper and
liner body layer with higher yields than corresponding kraft pulps.
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5.2 Scale of Operation: The above described tests were conducted in a laboratory scale digester of 20-
liter volume.
NS-AQ pulping has also been tested in full scale mill trials. All together 15,000 tons of fully
bleached pulp was made.
5.3 Stage of Development: Fully implemented. See 5.4.
5.4 Level of Commercialization: The produced pulp was tested in various end uses with pretty good
results. However, there still remains many difficulties unsolved in the chemical recovery system
and the research work on NS-AQ process is currently not going on.
5.5 Material/Energy Balances and Substitutions:
Quantity After
N/A
N/A
N/A
N/A
Material Category Quantity Before
Waste Generation: N/A
Feedstock Use: N/A
Water Use: N/A
Energy Use: N/A
6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
The NS-AQ process offers many advantages compared to the kraft process. Some of them are listed
below:
-higher pulping yield
-fully bleached softwood pulps 5-7%-points
-fully bleached birch pulp 1-3%-points
-liner board body pulp 15%-points
-this means lower costs for wood raw material
-higher brightness of unbleached pulp
-easier to bleach to high brightnesses (less bleaching stages)
-no foul odor of liquor or condensates
-direct contact evaporation possible without odor problems
-many papermaking properties are exceptionally good despite the high yield
-sulfur-free crude turpentine and tall oil can be produced
-smaller inert load in chemical cycle
8.0 Obstacles, Problems and/or Known Constraints
The main drawbacks of the NS-AQ process are:
-pulping time at 175°C is about 25-30% longer than in kraft pulping at 170°C when aiming at a
kappa number of 35-40
-delignification stops at a kappa level of 40, which means high total active chlorine consumption
in bleaching or alkaline oxygen stage to start the bleaching
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-some NaOH needs to be added (pH 10) to the spent liquor to avoid sticky precipitation in
evaporation
-if oxygen stage is used for fully bleached pulps, additional NaOH is needed, which means that a
small causticizing plant would be necessary
- the heat value of spent liquor is lower than that of kraft pulping black liquor
-the preparation of the cooking liquor containing mainly Na2SO3 and Na2CO3 is rather
complicated. A recovery boiler is needed and the green liquor has to be converted to cooking
liquor.
9.0 Date Case Study Was Performed: United Paper Mills Rauma pulp mill (previously Rauma-Repola) made
fullscale mill trials with NS-AQ process during the years 1989-90.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and conference proceedings.
10.2 Citation: 1. Aziz, S. and Sarkanen, K., Organosolv pulping - a review, Tappi Journal, March
1989, pp. 169-175.
2. Ojanen, E., Tulppala, J. and Virkola N-E., Neutral sulphite anthraquinone (NS-AQ) cooking
of pine and birch wood chips, Paperi ja Puu-Paper and Timber, No 8, 1982, pp. 453-464
3. Tikka, P., Tulppala, J. and Virkola, N-E., Neutral sulphite AQ pulping and bleaching of
pulps, Tappi Proceedings, International Sulfite Pulping Conference, 1982, pp. 11-21
10.3 Level of Detail of the Source Material: Additional information on the pulping tests conducted is
available in the source material.
10.4 Industry/Program Contact and Address: Jukka Kettunen, The United Paper Mills Ltd., Rauman
Sellu, P.O.Box 250, 26101 Rauma, Finland, phone: 938-3311, fax: 938-333404.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit.P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulping effluent.
11.2 Process type/waste source: Chemical pulping.
11.3 Cleaner Production Technique: Organosolv pulping, NS-AQ pulping, Neutral sulfite-
anthraquinone pulping.
11.4 Other Keywords:
11.5 Country Code: Finland
12.0 Assumptions
13.0 Peer Review
Yes
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulping effluent, chemical pulping, organosolv pulping, NS-AQ pulping, neutral sulfite-
anthraquinone pulping
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Alkaline Sulfite Anthraquinone (ASAM) methanol pulping process produces pulps with
strength properties comparable to kraft pulp using chlorine-free bleaching of softwood pulps with minimal
environmental impact.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Kraftanlagen Aktiengesellschaft, Im Breitspiel 7, Postfach 103420, W-6900 Heidelberg, Germany.
4.0 Cleaner Technology Category
Kraft pulping is not allowed in Germany due to emissions to the air and the unacceptable effluent load.
Sulfite pulp production is limited, because this process is not suitable for all wood, including the abundantly'
available pine. As a result, the pine wood must be exported and pulp imported from other countries.
Sulfite pulp production could make a come-back in a cleaner form from the ASAM process.
5.0 Case Study Summary
5.1 Process and Waste Information: The process consists of three main sections. These are digestion
and brownstock washing, screening and 4-stage bleaching, evaporation and methanol rectification.
The chips are pre-steamed for 15 minutes before the cooking liquor is added. A typical liquor
consists of up to 25% inorganics, calculated as NaOH, based on dry wood, where 20% are
Na^O3 and the remaining 5% are added as NaOH or Na^O3 or a combination thereof, 10-20%
methanol, and around 0.1 % of anthraquinone (AQ) as a catalyst. Cooking temperatures of 170-
1800C must be maintained for 90-180 minutes. The cooking process can be modified to make
different pulp grades for papers and boards by changing the cooking liquor's composition and
pulping conditions.
Because unbleached ASAM pulp has very low lignin content, almost no extractives, and
considerable initial-brightness, chlorine free bleaching is possible. After an initial oxygen
delignification, ozone is used in a specially built reactor. Ozone has to be generated and
consumed onsite. Hardwood and softwood pulps can be bleached to approximately 90% ISO
brightness with the sequence OZWP.
The filtrates from the bleaching stage are led countercurrent and are mixed with the black liquor
after brownstock washing. This enables the dissolved organic substances and the inorganic
bleaching chemicals to be caught in the black liquor.
The chemical recovery process stages are comparable to those used with sodium based sulfite
pulping, after the methanol has been stripped off the waste liquor evaporation and combustion,
inorganic chemical conversion, cooking liquor preparation, and by-product making. Methanol
separation and chemical conversion are added as different process steps to the recovery compared
with kraft pulping. Most methanol can be condensed from the relief gases when the digester is
opened, and the remaining part is stripped from the black liquor.
The AQ is almost completely dissipated in the cook, and none will be reclaimed.
As much water as possible is evaporated from the black liquor. The strong black liquor is burned
in a boiler under reducing conditions. In the chemical recovery furnace, inorganic salts are
recovered from the spent liquor in the smelt as sodium sulfide and sodium carbonate, and the
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energy values of the organic materials are recovered to make steam and electricity for the pulp
mill. In the chemical conversion the inorganic chemicals Na^O3 and Na^O3 are regenerated.
5.2 Scale of Operation: The pilot plant capacities are:
Digestion and brownstock washing, assuming two cooking cycles, 1.3-1.5 moisture free metric
tons/day
Screening and bleaching 4.6-5.0 moisture free metric tons/day
Water evaporation 29.0 metric tons/day.
5.3 Stage of Development: The process was developed by Professor Patt and Dr. Kordsachia at the
University of Hamburg. Energy systems manufacturer Kraftanlagen Heidelberg bought the
process and patented it. Feldmuhle co-operated in the practical aspects of the process. The
ASAM pilot plant was started in November 1989 and was dedicated at Feldmuhle's Baienfurt mill
in early April 1990
5.4 Level of Commercialization: See 5.3. Kraftanlagen Heidelberg has recently filed worldwide
patent applications for the process.
Conventional machinery and components can be used.
5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before Quantity After
Waste Generation:
COD
BOD5
AOX
Feedstock Use:
Water Use:
Energy Use:
N/A
N/A
N/A
N/A
N/A
N/A
< 10 kg/ADt pulp
<0.5 kg/ADt
0
N/A
N/A
N/A
6.0
Economics*
6.1 Investment Costs: In regard to green field mill, investment cost for an ASAM mill are about the
same as for a kraft mill. By July 1991 Kraftanlagen Heidelberg will have spent DEM 20 million
for R&D, with 30% of the amount paid by the FRG's Ministry of Research and Technology.
6.2 Operational and Maintenance Costs: Due to higher yields in ASAM cooks, savings in wood cost
in case of hardwood of about 6-10% and in case of softwood of about 4-6% are gained. Cost for
make up of cooking chemicals (Na2SO4, NaOH) are slightly higher for ASAM; reclaim efficiency
of methanol is about 99% Under certain conditions, caustizing plant and lime kiln are not
required.
According to our calculation, an OZEP respective an OEP sequence results in lower operating cost
than an OCDED or an C/D E/O DED sequence. Actual costs for ozonization largely depend on
prices for chemicals and electrical energy, which vary from country to country and from mill to
mill. Ozone consumption usually ranges from 5 to 8 kg/ton of pulp; production cost for ozone
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6.3
are estimated to be: in Finland(February 1991) US$ 1.28/kg, in Austria (June 1991) less than US$
1.75/kg and in Germany (June 1991) US$ 1.45/kg.
Savings in effluent treatment are gained due to reduced flows.
An ASAM mill is as self-supporting in both heat and power as a modern kraft mill.
Payback Time: Payback time is as for a kraft mill.
7.0 Cleaner Production Benefits
No reduced sulfur compounds are made during the ASAM process and methanol is kept in a closed cycle
system.
ASAM pulp can be bleached to high brightness in chlorine free sequences, and as a result, there are no
toxic, difficult-to-degrade organic chlorine compounds. The bleached pulp is also free of dioxins and •
furans.
Poisonous and oxygen consuming substances are nearly at a zero level in the effluents. Official wastewater
quality requirements as stated in Germany can be met easily, including the limits for COD and BOD, and
for toxicity to maritime life. AOX will be zero because no chlorine chemicals are used, and tor toxicity
to maritime life. High yield and superior quality are among the economies the ASAM process offers in
comparison with other pulping processes. It also permits the use of some unbleached hardwoods for the
production of writing and printing papers.
The chemicals in ASAM process can be recovered together because the same base is used in the bleach
plant as in the cook. The process can be used with a wide variety of raw materials, and there is no special
requirements for debarking or chip quality.
8.0 Obstacles,-Problems and/or Known Constraints
Due to volatility of pulping chemicals no leaks and spills can be tolerated, both for environmental and
economic reasons.
9.0 Date Case Study Was Performed: The pilot plant operation started in November 1989 with the departments
cooking and evaporation including the methanol recovery. The inauguration was held in April 1990. In
June 1990 the bleach plant went on line.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article, conference proceedings, brochures and unpublished
material.
10.2 Citation:
(1) Zimmermann, M., Patt, R., Kordsachia, O., and Hunter, W.D., ASAM Pulping of Douglas-fir
Followed by a Chlorine-free Bleaching Sequence, Tappi Journal, November 1991, pp. 129-134;
(2) Kopfmann, K., Conversion of an Existing Kraft Pulp Mill to an ASAM Mill, Tappi Proceedings,
Pulping Conference, November 1991, pp. 925-931;
(3) Fuchs, K., Rimpi, P., and Brown, C., Chemical Recovery System for an ASAM Mill, Tappi
Proceedings, Pulping Conference, November 1991, pp.259-270;
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(4) The Right Approach to Pollution-free Pulping, ASAM Pilot Plant Confirms Laboratory Test Results,
Kraftanlagen Heidelberg, brochure, 8 p.;
(5) The Right Approach to Pollution-free Pulping, AS AM-Report 1, Kraftanlagen Heidelberg, brochure,
8 p.;
(6) Der Richtige Weg zur Umweltfreundlichen Zellstoff-erzeugung, Kraftanlagen Heidelberg, brochure,
8 p.;
(7) Fuchs, K., The ASAM Process, Kraftanlagen Heidelberg, 13 p.;
(8) Patt, R., Schubert, H-L., Kordsachia, O., Oltmann, E., and Ridder, W., The ASAM Process -
Competitor to Kraft Pulping?, 24 p.
10.3 Level of Detail of the Source Material: Additional information is available in the source material.
10.4 Industry/Program Contact and Address: Kraftanlagen Aktiengesellschaft, Im Breitspiel 7, Postfach
103420, W-6900 Heidelberg, Germany, phone: -6221/94-01, fax: -6221/94-1707, telex: 461831.
10.5 Abstractor Name and Address: Mrs. Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: Chemical pulping, Delignification, Closed cycle mill, Sulfite pulping
with methanol, Dissolved lignin
11.3 Cleaner Production Technique: ASAM pulping, Counter current flow of bleach filtrates, AOX
elimination, Anthraquinone
11.4 Other Keywords:
11.5 Country Code: Germany.
12.0 Assumptions
13.0 Peer Review
Yes (No 1 in 10.2) others unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chemical pulping, Delignification, Closed cycle mill, Sulfite pulping with methanol, Dissolved lignin,
ASAM pulping, Counter current flow of bleach filtrates, AOX elimination, Anthraquinone
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
Headline: The ORGANOCELL-organosolv pulping process produces easy to bleach, sulphur-free pulps
bleachable with chlorine products and genrates sulfurfree lignin as a by-product.
SIC/ISIC Code: 13411,13511
Name and Location of Company:
The ORGANOCELL process has been developed by ORGANOCELL GmbH, a subsidiary of Technocell
AG, Both companies with main office in Muenchen, Germany.
4.0 Cleaner Technology Category
In a country with no kraft pulping industry and with stringent environmental regulation, the
ORGANOCELL process is the only means of producing bleached pulps from locally available raw
materials, such as hardwoods, resinous softwoods as well as annual plants without the use of sulfur and
chlorine containing bleaching chemicals. The ORGANOCELL process is a complementary pulping process
to existing pulping processes. The ORGANOCELL process offers the user the means of producing
chemical pulps without sulfur emissions. Bleach plant effluent streams are not contaminated with
chlorinated waste products since ho chlorine products are used for bleaching purposes.
5.0 Case Study Summary
5.1
Process and Waste Information: The ORGANOCELL process is essentially an all-alkaline pulping
process. In the operation of the demonstration plant the wood chips are initially impregnated at a
temperature of 110-140°C with a mixture of alcohol and water. Either methanol or ethanol can be
used in the process.
From the impregnation stage the softened wood chips are transported into the digester where alkali
and catalytic amounts of anthraquinone (AQ) are added. The pulping liquor is indirectly heated to
165-170°C, which produces a pressure of approximately 13 bar in the dome above the chip pile
inside the digester, due to the methanol, 25-30% by volume, in the aqueous pulping liquor. The
wood chips are then cooked for a period of 120 minutes, the alkali charge and the cooking time
depending on the degree of delignification of the wood chips desired.
From the cooking zone, the delignified wood chips move inside the digester downward into the
high-heat wash zone where they are washed countercurrently with wash liquor from the pulp
washers following the in-digester wash zone. Once discharged from the digester, the pulp is scree-
ned on a knotter screen to remove knots and coarse uncooked wood pieces and then sent to the
bleach plant. In the first bleaching stage, oxygen and alkali are mixed with the pulp.
While in the oxygen stage, the main objective is to remove residual lignin from the pulp fiber
without imparting damage to the cellulose during the alkaline oxygen treatment, the bleaching stages
following the oxygen stage bring the most brightness improvements.
Attached to the ORGANOCELL demonstration plant is an experimental plant for the electrolytic
recovery of sodium ions from black liquor. The plant is being operated on an intermittent basis to
collect sulfur-free lignin and also to gain operational experience in the operation of said plant.
The ORGANOCELL process is capable of producing a wide range of pulps from hardwoods,
softwoods and annual plants. ORGANOCELL type pulps are equal in quality to Kraft pulp
properties. These pulps are bleached without chlorine products to quite high brightness levels.
AOX discharges from bleach plants are insignificant.
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6.0
7.0
5.2 Scale of Operation: The demonstration plant is capable of producing up to 5 tpd bleached pulp.
5.3 Stage of Development: The demonstration plant can be operated on a continuous basis, 24
hours/day.
5.4 Level of Commercialization: Since 1988, ORGANOCELL GmbH is the owner of the Bayerische
Zellstoff GmbH at Kelheim, Germany. The mill used to produce 65,000 tpy fully bleached
specialty pulps by a Mg-bisulfite process, however, was to be shut down because of environmental
reasons. In early 1989, engineering was started to convert the mill to the ORGANOCELL process
with a yearly capacity of 150,000 tons fully bleached softwood pulp. The pulp produced will be
bleached totally chlorine free. Start-up of the new plant will be during the third quarter 1992.
The rebuild of the Kelheim mill is carried out by the engineering company ORGANOCELL
THYSSEN GmbH. The same company will also handle greenfield pulp mill projects as well as mill
rebuilds to the ORGANOCELL process world-wide.
5.5 Material/Energy Balances and Substitutions: The operation of conventional pulp mills is characte-
rized by the emission of sulfur containing products into the air. With the conversion of a mill to
the ORGANOCELL process, these emissions no longer exist. The ORGANOCELL process does
not produce any hazardous waste by-products. Since no sulfur is used in the process, by-products
from the process can either be used in other industries (e.g., cement industry) or can be disposed
by burning.
With the operation of the mill at Kelheim with an expanded capacity of 150,000 tpy, wood residues
from several hundred saw mills in the region will be used. As a consequence, this will result in
a more efficient use of regionally available fiber materials.
It is anticipated that the amount of fresh water used in the process will be approximately 30 cubic
meters per ton pulp produced. The,mill will be energy self sufficient by burning the organic wood
degradation products produced in the pulping process. Some natural gas will be required in the
chemicals recovery area of the mill to rebum calcium carbonate to lime.
Economics*
6.1 Investment Costs: The ORGANOCELL process is the first solvent pulping process commercially
implemented for the use of softwoods. Investment cost as well as operational cost for an
ORGANOCELL type pulp mill will be lower than those for a Kraft mill since no odor control
equipment will be required. The chemicals recovery portion of the plant is also simpler than that
of a Kraft mill due to the absence of sulfur from the process.
6.2 Operational and Maintenance Costs: These costs will be lower than for a conventional Kraft mill
since no odor control equipment will have to be operated or maintained.
6.3 Payback Time: The payback time will be the same, if not shorter, than for a conventional Kraft
mill due to the lower investment cost for an ORGANOCELL type pulp mill.
Cleaner Production Benefits
The ORGANOCELL process produces a sulfur-free pulp as well as sulfur-free lignin. The pulp can be
bleached to market-accepted brightness levels without any chlorine products.
8.0 Obstacles, Problems and/or Known Constraints
ORGANOCELL type pulps are processed in the demonstration plant in a manner similar to Kraft pulps.
No special equipment is required and plant operating practices are similar to those of a Kraft mill. Pulp
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is washed inside the digester countercurrently with wash water from the brown stock washers. Fresh water
is applied to the last stage of the brown stock washers and the filtrate cascaded back into the high-heat wash
zone of the digester and ultimately into the evaporators/chemicals recovery plant.
In the 5-year operation of the demonstration plant, no unstable operating situations have ever been
encountered. Pulping trials with mixed North American hardwoods have produced pulps which have
physical properties superior to those which are normally produced from the same fiber source by the Kraft
process.
9.0 Date Case Study Was Performed: The ORGANOCELL demonstration plant, located in a residential area
of Muenchen, Germany, has been operated since 1987 without any objectionable impact on the surrounding
area.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
10.2 Citation:
(1) Dahlmann, G. and Schroeter, M.C., The Organocell Process- Pulping with the Environment in Mind,
Tappi Journal, April 1990, pp. 237-240;
(2) Aziz, S. and Sarkanen, K., Organosolv Pulping - A Review, Tappi Journal, March 1989, pp. 169-175;
(3) Aziz, S., McDonough, T., Thompson, N. and Doshi, M.R., Solvent Pulping - Promise and Programs,
Tappi Journal, February 1988, pp. 251-256;
(4) Newsfront, Pulp Bleaching - The race for Safer Methods, In Chemical Engineering, January 1991, pp.
37-43;
(5) Pride, D., Old Pulps for New, Paper, 6 November, 1990, pp. 26-28;
(6) Pulping Technology - Beyond the Kraft Process, Asia Pacific Pulp & Paper, May 1991, pp. 15-17.
10.3 Level of Detail of the Source Material: Some additional information, specially on pulp properties,
N is available in the source material used.
10.4 Industry/Program Contact and Address: Gerhard Dahlmann, chief executive officer and Martin C.
Schroeter, Dr., project manager, Organocell Thyssen GmbH, Brauhausstrasse 4a, D-8033 Planegg,
Germany, phone: 0 89/8 56 08-0, fax: 0 89/8 56 09-13.
10.5 Abstractor Name and Address: Gerhard 'Dahlmann, chief executive officer and Martin C.
Schroeter, Dr., project manager, Organocell Thyssen GmbH, Brauhausstrasse 4a, D-8033 Planegg,
Germany, phone: 0 89/8 56 08-0, fax: 0 89/8 56 09-13.
11.0 Keywords
11.1 Waste type: Pulp plant effluent
11.2 Process type/waste source: Pulping, Chemical pulping, Organosolv lignins
11.3 Cleaner Production Technique: Environmental control, Organosolv pulping. Solvents, Methanol.
Alcohols, ORGANOCELL process
11.4 Other Keywords:
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11.5 Country Code: Germany.
12.0 Assumptions
13.0 Peer Review
Yes (all articles in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp plant effluent, Pulping, Chemical pulping, Organosolv lignins, Environmental control, Organosolv
pulping, Solvents, Methanol, Alcohols, ORGANOCELL process
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Alcell-organosolv pulping process produces high-quality, fully bleached pulps without water-
soluble waste or noxious gases.
2.0 SIC/ISIC Code: 13411,13511
3.0 Name and Location of Company:
Repap Enterprises Inc., Newcastle, New Brunswick, Canada.
4.0 Cleaner Technology Category
The Alcell-process uses.simple aqueous ethanol as a pulping liquor. Organosolv pulping methods offer a
means of curtailing volatile sulphur compound emissions in digestion and chlorinated organics in bleach
plant effluents. The simplicity of organosolv pulping makes it possible to establish minimills (200 tpd
capacity) in locations with limited wood supplies.
5.0 Case Study Summary
5.1 Process and Waste Information: Repap Enterprises started up a mill at Newcastle to demonstrate
and test a proprietary organosolv pulping method known as Alcell process. The pulping process
consists of the following steps. The key to the process is to sequence pulping in three stages.
Preheated chips are packed in the digester using steam, and the steaming is continued to displace
air from the chips. Preheated solvent, 50% (weight/weight) denatured ethanol/water mixture that
has been previously used as a wash liquor for two earlier batches is pumped in and rapidly brought
up to pulping temperatures of 190-200°C, corresponding to an operational pressure of 400-500 psig.
The liquor is continuously circulated during the pulping. At the end of this period, the liquor is
displaced by wash liquor that was used in the second washing stage of the previous batch. The
displaced liquor flows to the lignin and sugar recovery system. The third-stage wash liquor is
displaced by fresh liquor and flows into an storage tank for use in the second stage. The second
stage-wash liquor is drained into another tank for use in the digester.
At this point, the digester contains soaked, delignified chips and alcohol-water vapor at pulping
temperature and pressure. It is depressurised and the departing vapor is condensed for reuse as
fresh pulping liquor. Finally, the alcohol remaining in the digester is driven off by steaming. The
pulp is diluted with water and pumped out of the digester for cleaning and bleaching treatments.
The first-stage spent liquor entering the by-product recovery area is first flashed and then diluted
with process water to precipitate the dissolved lignin. After settling, the solid lignin is separated
by centrifugation, washed and dried. The filtrate enters a distillation tower, where alcohols and
some acetic acid and furfural are recovered. Finally, the remaining aqueous liquor is further
evaporated to a sugar syrup.
The facility has produced pulp from individual species as well as mixtures of northern hardwoods,
aspen, birch and maple. The pulp has been bleached in the adjacent kraft mill's bleach plant,
mostly in combination with softwood kraft, using conventional oxygen bleaching procedures and
further bleaching by DED sequences. In general, the pulps are more easily bleached than kraft.
The physical properties of bleached Alcell and kraft pulps were comparable. The specific bending
stiffness of Alcell pulps is improved over kraft pulps. It is an advantage in alkaline papermaking,
where significant filler is used in the sheet.
The product lignin can amount to about 18% by weight of the dry wood charge. It is highly
hydrophobic, contains no measurable sulfur and very low ash, and as a consequence is quite distinct
from either lignosulfonates or kraft thiolignin. It is a uniform product with a number average
molecular weight of about 1000 daltons, a softening point of about 145°C, and a glass transition
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6.0
5.2
temperature of about 100°C. The dried and bagged product has a moisture content of less than 3 %,
and a median particle size of 20-40 um.
The by-product furfural, which is recovered as an impure side draw, is upgraded and sold.
Scale of Operation: The facility can produce more than 15 tons of unbleached pulp per day. More
than 5 tons of Alcell lignin are being produced daily.
5.3 Stage of Development: A demonstration plant of 15 tpd capacity is working and a commercial-scale
mill with an approximate capacity of 300 metric tons/day is planned to be designed.
5.4 Level of Commercialization: The Alcell process is patented and it can be accomplished on existing
mill equipment.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
Economics*
6.1
Investment Costs: The facility in Newcastle has cost in excess of 95 million CAD (1989 or 1991)
to build and operate.
Without a need for a recovery furnace, lime kiln, causticizers, and brownstock washers, the Alcell
process has a substantial capital cost advantage over a comparably scaled kraft mill.
6:2 Operational and Maintenance Costs: See 6.1.
Without the recovery furnace and other high-maintenance equipment, an Alcell mill should have
lower maintenance and operating labor costs. On the other hand, the recovery and sale of lignin
and other by-products creates additional demand for externally generated energy. So the utility and
cooking chemical cost is higher.
6.3 Payback Time:
7.0 Cleaner Production Benefits
' The process is odorless, is free from TRS (total reduced sulfur) and methyl mercaptans, is free from liquor
dregs and lime grits, and produces minimal amounts of knots and rejects. The major effluent, apart from
the bleach-plant effluent, is the stillage evaporator condensate, which contains only easily treated BOD
(mostly acetic acid, ethanol, and a few other minor organic volatiles). The bleach-plant effluent, as
currently anticipated for the 300-metric-ton/day mill, will contain no dioxins or furans, and AOX levels
should be below 1 kg/metric ton of pulp. An Alcell mill requires far less water than a kraft mill.
8.0 Obstacles, Problems and/or Known Constraints
Due to volatility of pulping chemicals no leaks and spills can be tolerated, both for environmental and
economic reasons.
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9.0 Date Case Study Was Performed: The demonstration plant at Newcastle started up in March 1989.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
10.2 Citation:
(1) Pye, E.K., and Lora, J.H., The Alcell Process, Tappi Journal, March 1991, pp. 113-118;
(2) Pride, D., Old Pulps for New, Paper, 6 November, 1990, pp. 26-28;
(3) Aziz, S. and Sarkanen, K., Organosolv Pulping- A Review, Tappi Journal, March 1989, pp. 169-175;
(4) Aziz, S., McDonough, T., Thompson, N. and Doshi, M.R., Solvent Pulping - Promise and Programs,
Tappi Journal, February 1988, pp. 251-256.
10.3 Level of Detail of the Source Material: Some additional detail information is available in the source
material used.
10.4 Industry/Program Contact and Address: Mrs. Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205,
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf.
10.5 Abstractor Name and Address: Same as in 10.4.
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: Chemical pulping, Delignification, Organosolv lignins
11.3 Cleaner Production Technique: Organosolv pulping, Solvents, Alcohols
11.4 Other Keywords:
11.5 Country Code: Canada.
12.0 Assumptions
13.0 Peer Review
Yes (all articles in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
, factors.
Keywords: Chemical pulping, Delignification, Organosolv lignins, Organosolv pulping, Solvents, Alcohols
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DQCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Sulphur- and chlorine-free oxygen-alkali cooking process
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The Pulp and Paper Research and Production Complex (VNPObumprom), 194021, St Petersburg, Soviet.
4.0 Cleaner Technology Category
The process produces sulphur-and chlorine-free pulps. The untreated effluent has been shown to be totally
non-toxic.
5.0 Case Study Summary
5.1 Process and Waste Information: The process uses oxygen-alkali cooking and a type of pulsed
digester. Conventional technology is used before and after pulping. Pre-steaming is necessary.
The digester vessel contains a number of plates that divide it into zones. Gaseous oxygen is
dispersed at each of the plates and the digester is agitated by pulsation. This pulsation action
creates a coarse fibre screening and helps in the fine dispersion of the oxygen.
The three process components - oxygen, chips, cooking liquor - are in constant motion so there are
no dead zones within the digester. The process achieves three things: pulping, screening and
degradation of non-easily oxidizable organics.
Three possible alkaline agents can be used: ammonium hydroxide, sodium carbonate or sodium
hydroxide. There is no difference in pulp quality, no matter which agent is used. Cooking time
is four hours for hardwood, a little longer for softwood. Studies are now under way to reduce the
cooking time by using catalysts.
• All chemical agents are recovered in the process and the cooking liquor is evaporated and burned.
Crystalizers are. used. The evaporators handle up to 50% solids, and there is no problem with
fouling. Because oxygen is used as a cooking agent, the resin fatty acids are oxidized during the
pulping process.
The cooking process occurs at the surfaces of the chips and hydrodynamic forces ensure continuous
removal of fibres out of the digester. When fibres at the surface have been delignified, they are
removed, exposing a new surface. Therefore, chips of standard thickness can be used. As the
outer layers detach during delignification, they move to a discharge zone. Chip quality does not
play a big role. Also, various wood species may be cooked together with no negative effect on pulp
quality.
Bleaching is a three-stage process using oxygen and other oxygen-containing substances (peroxide)
and brightness levels as high as 87 may be achieved. The bleached pulp does not lose mechanical
strength properties. With no chlorine needed for bleaching, the process has eliminated chlorinated
organics.
5.2 Scale of Operation: There is a 0.5 tpd pilot plant at the Sjas mill near St Petersburg.
5.3 Stage of Development: Pilot stage.
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7.0
8.6
9.0
10.0
5.4 Level of Commercialization: A semi-industrial size plant, 35,000 tons per annum, is under
construction with start-up due in 1992. The equipment needed is commercially available. Digester
construction is of the same steels used in Kamyr digesters.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use: O2
Water Use:
Energy Use:
Pulp yield:
Quantity Before
N/A
N/A
N/A
N/A
100
Quantity After
N/A
400 kg/t pulp
N/A
N/A
105-107
6.0 Economics*
6.1 Investment Costs: Production and equipment costs are 20% below those of kraft, based on studies
done by an independent foreign firm.
6.2 Operational and Maintenance Costs: See 6.1.
6.3 Payback Time:
Cleaner Production Benefits
See 4.0
Obstacles, Problems and/or Known Constraints
Date Case Study Was Performed: The semi-industrial plant will start-up in 1992. At the same time,
equipment for producing 100,000 and 250,000 tons per annum is being developed and designed.
Contacts and Citation
10.1 Type of Source Material: Journal article and conference proceedings.
10.2 Citation:
(1) Rodden, G., Now It's Glasnost for Pulping, Paper, 4 September, 1990, p. 15.;
(2) Germer, E.I., Oxygen-alkaline Delignification Catalysis, Ligno-Cellulosics - Science, Technology,
Development and Use, (Ed.) J.F.Kennedy, G.O. Phillips, P.A. Williams, Ellis Horwood 1992, pp. 227-
237.
10.3 Level of Detail of the Source Material: Additional information is not available in the source
material.
10.4 Industry/Program Contact and Address: Mrs. Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205,
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex P?972 vttha
sf.
10.5 Abstractor Name and Address: Same as in 10.4.
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11.0 Keywords
11.1 Waste type: Pulp plant effluent
11.2 Process type/waste source: Chemical pulping, bleaching
11.3 Cleaner Production Technique: Oxygen-alkali cooking, Oxygen bleaching, Peroxide bleaching
11.4 Other Keywords: Sulphur-free, Chlorine-free, Non-toxic
11.5 Country Code: Soviet.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp plant effluent, Chemical pulping, bleaching, Oxygen-alkali cooking, Oxygen bleaching. Peroxide
bleaching, Sulphur-free, Chlorine-free, Non-toxrc
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Modified Continuous Cooking (MCC) process adapts the principles of extended
delignification to continuous pulping.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The method has been applied in about ten mills in Scandinavia, North America, and Japan. One of them
is at Iggesund in Sweden.
4.0 Cleaner Technology Category
The principles of extended delignification have been adapted to continuous pulping. The process is known
as modified continuous cooking (MCC). Kappa number reductions of 8 units for softwood and 4-5 units
for hardwood have been accomplished without loss of strength properties. About 20-25 % less total active
chlorine is needed to bleach the pulp to about 90% ISO brightness, compared to the conventional kraft
pulp.
The MCC process is a process that produces pulps of high viscosity suitable for oxygen delignification.
MCC, oxygen delignified, bleached pulps were prepared using bleaching sequences with and without
chlorine, using a four stage sequence of (C+D)(EO)DD and D(EOP)DD. At 100 % substitution of chlorine
dioxide for chlorine in the first stage AOX is less than 1,0 kg/ton in the effluent before external treatment,
chlorinated phenols are 98% eliminated, and the dioxin content of the bleached pulp is close to the limit
of detection.
5.0 Case Study Summary
5.1 Process and Waste Information: The MCC process rectifies the drawbacks in a conventional,
continuous kraft cook. The effective alkali concentration through the duration of the cook is evened
out by decreasing it at the beginning of the cook and increasing it at the end. This makes up for
the high effective alkali concentration at the beginning and low concentration at the end of a conven-
tional kraft cook.
In a conventional cook, the high bulk lignin concentration at the end of the cook hinders diffusion
of dissolved lignin out of the chips, causing reprecipitation. This is tackled by reducing the
concentration of bulk lignin from the digester and adding fresh chemicals, accomplished by carrying
out the final cooking stage countercurrently, where white liquor is also added.
The MCC process has been accomplished through the modification of two-vessel Kamyr continuous
digesters to allow both the introduction of white liquor at several points and the countercurrent tlow
of the liquor during the final cooking phase.
A nonchlorine fiber line, which has been commissioned, consists of a digester for medium-
consistency cooking and a medium-consistency, oxygen-delignification stage, followed by an
efficient post-oxygen washing stage with pressure diffuser and a wash press. Bleaching is carried
out with the sequence (C+D)(EOP)DD with a pressurized extraction stage and a pressure diffuser
for efficient washing. If required, the first stage can be carried out without chlorine.
Compared with conventional bleaching, a nonchlorine alternative has some significant effects on
the environment. AOX is less than 1.0 kg/ton in the effluent before external treatment.
Chlorinated phenols are 98% eliminated. Finally, the dioxin content of the bleached pulp is
extremely low, close to the limit of detection.
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6.0
5.2 Scale of Operation: The modified continuous cooking process has been successfully introduced in
the pulp industry. Today the method has been applied in about ten mills. A laboratory study was
conducted to show the bleachability of MCC pulp. The bleaching sequences were (C + D)(EO)DD
and D(EO)DD.
5.3 Stage of Development: The MCC process has been successfully introduced in mill scale.
5.4 Level of Commercialization: The MCC process has been developed by Kamyr AB and it has been
commercialized. The commercial mills using MCC technology reported are Ahlstrom's mill in
Varkaus, Finland, the Metsa-Botnia's mill in Aanekoski, Finland and the Korsnas' mill in Gavle,
Sweden.
5.5 Material/Energy Balances and Substitutions
Material Category Quantity Before
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs: The extra chemical costs for D(EOP)DD bleaching are about
$10/ton (1989) or less, a reasonable cost when compared with conventional alternatives.
6.3 Payback Time:
7.0 Cleaner Production Benefits
The above mentioned fiber line,which have been commissioned in a Scandinavian mill, can be regarded
as one of the most advanced in the world today, meeting current and future requirements for the
environment while still producing fully competitive pulp. It is possible to produce bleached pulp without
the use of chlorine, achieving brightnesses even above 90% ISO, the level required for the most demanding
market pulps.
8.0 Obstacles, Problems and/or Known Constraints
The absence of chlorine requires extra efforts in all process stages from cooking to final bleaching. For
final bleaching, the sequence D(EOP)DD is suitable, with some modifications of normal practice. In the
first stage, the chemical charge should be generous. Low-multiple alternatives are not relevant when chlo-
rine is absent. Also, in the enforced extraction stage, both temperature and oxygen pressure should be
high. Magnesium is a good viscosity protector in such an EOP stage and when the hydrogen peroxide is
absent.
9.0 Date Case Study was Performed: The MCC process has been operated on a commercial scale since 1983
10.0 Contacts and Citation
10.1 Type of Source Material: Journal Articles
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11.0
12.0
13.0
10.2 Citation:
(1) Dillner, B., Larsson, L. and Tibbling, P., Nonchlorine Bleaching of Pulp Produced by the Modified
Continuous Cooking Process, Tappi Journal, August 1990, pp. 167-172;
(2) Bowen, I.J. and Hsu, J.C.L., Overview of Emerging Technologies in Pulping and Bleaching, Tappi
Journal, September 1990, pp. 205-217;
(3) Heimburger, S.A., Blevins, D.S., Bostwick, J.H. and Donnini, G.P., Kraft Mill Bleach Plant
Effluents: Recent Developments Aimed at Decreasing Their Environmental Impact, Part 1, Tappi Journal,
October 1988, pp. 51-60;
(4) Pride, D., Old Pulps for New, Paper 6 November 1990, pp.26-28;
(5) Reduction of Chloro-organic Discharge in the Nordic Pulp Industry, Environment Report 1989:6E,
Prepared by Jaakko Poyry for The Nordic Council of Ministers, April 1989, 103 p.
10.3 Level of Detail of the Source Material: Additional information on pulp properties and effluent
characteristics is available in the source material.
10.4 Industry/Program Contact and Address: Dillner, Larsson and Tibbling, Kamyr AB, Karlstad,
Sweden.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
Keywords
11.1 Waste type:
11.2 Process type/waste, source: Kraft pulping, Oxygen delignification, Bleaching, Chlorination
11.3 Cleaner Production Technique: Modified continuous cooking, Extended delignification, Hydrogen
peroxide
11.4 Other Keywords: Strength properties, Chlorine dioxide
11.5 Country Code: Sweden.
Assumptions
Peer Review
Yes (all articles in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Kraft pulping, Oxygen delignification, Bleaching, Chlorination, Modified continuous cooking, Extended
delignification, Hydrogen peroxide, Strength properties, Chlorine dioxide
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Rapid Displacement Heating (RDH) process allows extended delignification requires less
active chlorine to bleach the pulps to 90% ISO brightness than in conventional kraft pulping and decreases
caustic soda consumption.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
United Paper Mills, Joutseno-Pulp, 54120 Pulp, Finland.
4.0 Cleaner Technology Category
The RDH process has proven itself not only by cooking stronger, more uniform pulp than conventional
systems, but by significantly reducing energy and chemical costs at the same time. Because the RDH
cooking process removes more lignin from wood chips than do conventional systems, less chlorine based
chemicals are needed in the bleaching phase (when cooking to lower kappa number). Caustic soda
consumption is also decreased.
5.0 Case Study Summary
5.1 Process and Waste Information: In the operating cycle of the RDH system, the batch digester is
charged with chips and packed with liquor or steam. The technique increases packing density by
up to 10%, thereby increasing pulp production per digester. The digester is then filled with warm
liquor of high sulfidity (low active alkali) at 100°C. The elevated pressure in the digester serves
to uniformly impregnate the chips. The warm liquor is displaced with hot white and black cooking
liquors. The digester is heated, and the cook continues to the desired H-factor.
At the end of the cook, displacement continues with washer filtrate until the pulp temperature is
below boiling point. The displaced liquor is collected in an accumulator. The digester is
discharged either with compressed air or by using pumping machine. Special heat exchangers are
employed to preheat the white liquor for the next cook to about 155 °C.
The pulp made via extended delignification was bleached to 90% ISO using 7.5% active chlorine
(11.7% for conventional kraft pulp). Caustic soda consumption decreased from 4.3% to 2.7%.
Pulp strength properties were equal to or superior to the conventional kraft pulp.
Unbleached and bleached pulp strength increased 10% at Joutseno. Displacement of the hot spent
liquor with washer filtrate is equivalent to a washing stage.
5.2 Scale of Operation: The capacity of the Joutseno Pulp mill is 800 ADt/day of bleached pulp.
5.3 Stage of Development: The RDH process has been developed by Beloit Corp. and it is on a
commercial stage of development. It was introduced to the industry in 1985.
5.4 Level of Commercialization: RDH is now on stream at Joutseno, Finland; S.D. Warren's
Westbrook mill; Bowater Southern at Calhoun, Term.; Fletcher Challenge Canada at Crofton, B.C.;
at Willamette in Bennettsville, S.C., and at Chung Hwa in Taiwan , while Potlatch will go on
stream with RDH at their mill in Cloquet, Minn., in about two years.
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5.5 Material/Energy Balances and Substitutions
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
. N/A
4GJ/t
Quantity After
N/A
N/A
N/A
2GJ/t
6.0 Economics
6.1 Investment Costs: The rebuild of an existing cooking department implies a significant investment.
6.2 Operational and Maintenance Costs: Slightly higher than in conventional cooking.
6.3 Payback Time: Over 10 years.
7.0 Cleaner Production Benefits
The RDH process is cooking stronger, more uniform pulp, reducing energy and chemical costs. It requires
less chlorine based bleaching and an added side benefit has been less soda loss over the washing line. The
fossil fuel consumption and the blow tank sulfur TRS emissions have been reduced.
8.0 Obstacles, Problems and/or Known Constraints
When rebuilding existing digesters for the modified cooking process, new screens have to be mounted in
the digesters and a number of large pressurized accumulators installed.
9.0 Date Case Study was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and an Environment report.
10.2 Citation: .
(1) Kaiser, M. and Pitre, R., Beloit's (RDH) displacement heating at Owens-Illinois, Valdosta, Georgia,
Tappi Journal, October 1986, pp. 45-48;
(2) Revolution in Kraft Pulping Technology - international Kraft pulpers gather in Maine to discuss RDH,
reference not known, pp. 26-28;
(3) Bowen, I.J. and Hsu, J.L., Overview of emerging technologies in pulping and bleaching, Tappi
Journal, September 1990, pp. 205-217;
(4) Reduction of Chloro-organic Discharge in the Nordic Pulp Industry, Environment Report 1989:6E,
Prepared by Jaakko Poyry for The Nordic Council of Ministers, April 1989, 103 p.
10.3 Level of Detail of the Source Material: Some additional information on the cooking cycle is
available in the source material.
10.4 Industry/Program Contact and Address: Seppo Pursiainen, United Paper Mills, Joutseno-Pulp,
54120 Pulp, Finland, phone: 953-3071, fax: 953-307378.
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10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type: Pulp mill effluent.
11.2 Process type/waste source: Kraft pulping, Extended delignification.
11.3 Cleaner Production Technique: Energy saving, RDH, Displacement heating.
11.4 Other Keywords:
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
Yes (all articles in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp mill effluent, Kraft pulping, Extended delignification, Energy saving, RDH, Displacement heating.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: "Super Batch" cooking process based on the principles of extended delignification been develo-
ped to reduce chlorinated compounds in the discharge of bleach plant effluent.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The first "Super Batch" cooking process will be started in 1992 at the Enocell Oy's pulp mill in Finland.
4.0 Cleaner Technology Category
The "Super Batch" cooking system was originally developed to make batch cooking more energy efficient.
The system has been modified to achieve extended delignification in some mills. Environmental influence
of effluents from bleaching of modified pulps is reported to be reduced if compared to conventional pulps.
5.0 Case Study Summary
5.1 Process and Waste Information: Extended delignification refers to modifications of pulping
processes, particularly the kraft processes, so as to prolong or extend the cooking to lower pulp
lignin content or the kappa number in the digester. The main operational drawbacks to extended
delignification are increased steam consumption and cooking time. These drawbacks have been
overcome by coupling this technology with "Super Batch" cooking.
In the "Super Batch" system the chips are preimpregnated and preheated with warm black liquor.
Impregnation improves air removal from the chips. The digester will be hydraulically filled with
liquor thus resulting in more uniform cooking.
Impregnation is followed by displacement with hot black and white liquor which gives very uniform
pulp quality, high strength, low shives content, good heat economy, higher yield and makes
extended cooking with good pulp properties possible.
Displacement with wash liquor at the end of cooking stops cooking reactions, cools the pulp and
improves pulp washing by lowering the final black liquor solids.
5.2 Scale of Operation: Extensive mill-scale test runs have been performed in a Scandinavian pulp mill
to observe the effects of extended cooking on the entire fiber line. The capacity of this mill is 900-
1000 AD metric tons/day of bleachable-grade softwood or hardwood sulfate pulp.
The amount of Super Batch type pulp for the' paper machine test runs was about 700 tons.
5.3 Stage of Development: Fully implemented, the first "Super Batch" mill is starting in 1992.
5.4 Level of Commercialization: The "Super Batch"- process has been developed by Sunds Defibrator
AB, Sweden. The equipment is readily available. Quantitative figures are based on actual mill
trials.
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S.S Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Quantity Before
AOX 3.0 kg/t of
softwood pulp
COD 70 kg/t of
softwood pulp
N/A
N/A
reduction in steam
Quantity After
(in bleaching effluent)
< 1.0 kg/t of softwood
pulp
< 30 kg/t of softwood
pulp
N/A
N/A
consumption 70%
Feedstock Use:
Water Use:
Energy Use:
6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
The "Super Batch" cooking system enables very low steam-consumption, washing in the digester and above
all significantly improves the pulp quality and pulp yield.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article and a brochure and conference material.
10.2 Citation:
(1) Pursiainen, S., Hiljanen, S., Uusitalo, P., Kovasin, K. and Saukkonen, M., Mill-scale experiences of
extended delignification with Super Batch Cooking method, Tappi Journal, August 1990, pp. 115-122:
(2) Super Batch Cooking System, Sunds Defibrator, brochure, 6 p.;
(3) Kovasin, K.K. and Tikka, P.O., Superbatch cooking results in superlow kappa numbers, Paper to be
presented at SPCI, ATICELCA, "New available techniques conference", Bologna, Italy, May 19-22, 1992,
18 p.
10.3 Level of Detail of the Source Material: Some additional information on the bleaching process used
and pulp properties is available.
10.4 Industry/Program Contact and Address: Paivi Uusitalo, Chief Engineer and Kari Kovasin, Manager
of R&D, Sunds Defibrator Rauma Oy, Pori, Finland.
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10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
. Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type: Bleach plant effluent, Chlorinated organic material
11.2 Process type/waste source: Sulfate pulping, Chemical pulping
11.3 Cleaner Production Technique: Extended delignification, Super Batch cooking, Modified pulps
11.4 Other Keywords:
11.5 Country Code: Finland.
12.0 Assumptions
Peer Review
13.0
Yes (No 1 in 10.2) and no (No 2 and 3 in 10.2).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Chlorinated organic material, Sulfate pulping, Chemical pulping, Extended
delignification, Super Batch cooking, Modified pulps.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Steam Explosion Pulping (SEP) uses less refining energy and may produce papers with strengths
superior to conventional CMP or CTMP.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Universitedu Quebec a Trois-Rivieres, Centre de recherche en pates et papiers, C.P.500, Trois-Rivieres,
Qc G9A 5H7 CANADA, phone: (819)376-5075, fax: (819)376-5148
4.0 Cleaner Technology Category
The SEP pulping process- produces hardwood/softwood pulp of strength comparable to that of low yield
hardwood kraft pulp. In addition, the SEP process uses appreciably less refining energy than the
conventional chemimechanical pulping processes. The environmental aspect of SEP process is similar to
that of ultra-high yield CMP as far as cooking effluent is concerned and is about 50% lower in bleaching
effluents.
5.0 Case Study Summary
5.1 Process and Waste Information: The steam explosion pulping process consists of the chemical
impregnation of chips, short time steam cooking, pressure release, refining and bleaching. In order
to protect the chips against oxydation during the cooking stage and to simultaneously develop
hydrophilic groups on the fiber surface during the steam treatment, the impregnation solution
contains antioxidant agents like Na^O3. To assure good swelling of chips and, at the same time,
to prevent acid hydrolysis leading to yield loss, swelling agents such as NaOH, Na^O3 or NaHCO3
are present especially during hardwood cooking. The chemical up-take is from 8% to 10%.
Short cooking time varying from 30 seconds to 6 minutes at temperatures varying from 170°C to
210°C leads to ultra-high-yield (90% +) explosion pulps of excellent pulp and paper properties.
Properties of exploded aspen, birch, maple or eucalyptus pulps are substantially better than those
of corresponding ultra-high-yield CTMP or CMP and can approach those of equivalent low yield
kraft pulps.
The brightness of exploded aspen pulps (60% +) can be increased to 80% + level by application of
4%H202.
In the case of hardwood pulps, the explosion pulps lead to considerably stronger papers when
compared to equivalent CMP/CTMP pulps but using substantially lower refining energy. The
strength can be up to 50% superior and the refining energy requirement up to 50% less than those
of conventional pulps.
5.2 Scale of Operation: In the experiments reported, eight tonnes of aspen chips were impregnated with
sulphite and caustic.
Mills of 100,000 tons of pulp per year have been evaluated by several consulting companies like
NLK, Nystrom Lee and Kobyashi, etc.
5.3 Stage of Development: Pilot stage.
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5.4 Level of Commercialization: The technology is ready for commercialization via Stake Technology
Ltd, Toronto, Canada.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
cooking
BOD
COD
bleaching
BOD
COD
Feedstock Use:
Water Use:
Energy Use: refining
Quantity Before
CMP
40-65
100-170
30
50
N/A
N/A
100
Quantity After
SEP
30-60
120-180
13-15
35
N/A
N/A
50
6.0 Economics*
Investment costs, operational and maintenance costs and payback time are available from Stake Technology
6.1 Investment Costs: The SEP require considerably lower capital investment (1/2) as well as operating
cost than low yield hardwood kraft pulping. The SEP process can be economical in much smaller
size (100 t/day).
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
Bleaching with one stage H^O2 is environmentally acceptable. Primary and secondary treatment of effluents
decreases BOD, solid substances and toxicity to very low levels.
8.0 Obstacles, Problems and/or Known Constraints
The new technology has to ^ proven on industria, ^ ^ ^^ proven ^ ^ ^
conventional CMP processes are completed with a continuous Stake-Tech Digester already being used on
industrial scale in biomass production (the continuous Stake Tech reactor replaces one refiner, therefore
the capital cost of SEP is comparable to that of CMP).
9.0 Date Case Study Was Performed: The results were reported in December 1990.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article and a book.
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11.0
12.0
13.0
10.2 Citation:
(1) Barbe, M.C., Kokta, B.V., Lavallee, H-C. and Taylor, J., Aspen pulping: A comparison of Stake
explosion and conventional chemimechanical pulping processes, Pulp & Paper Canada, 91:12 (1990), pp.
142-151;
(2) Kokta, B.V., Steam Explosion Pulping, book: Focher, B., Marzetti, A. and Crescenzi, V.(ed.), Steam
explosion techniques, Fundamentals and Industrial Applications, Gordon and Breach Science Publishers,
1991, pp. 163-206
10.3 Level of Detail of the Source Material: Additional information on the experimental procedures as
well as pulp properties is available in the source material.
10.4 Industry/Program Contact and Address: Bohuslav V. Kokta, Dr., Universite du Quebec a Trois-
Rivieres, Centre de recherche en pates et papiers, C.P.500, Trois-Rivieres, Qc G9A 5H7
CANADA, phone: (819)376-5075, fax: (819)376-5148
John Taylor, President, Stake Technology, 2838 HwY7, Norval, Ont, 2051KO, phone: 1-416 455
1990, fax: 1-416 455 2529
10.5 Abstractor Name and Address: Bohuslav V. Kokta, Dr., Universite du Quebec a Trois-Rivieres,
Centre de recherche en pates et papiers, C.P.500, Trois-Rivieres, Qc G9A 5H7 CANADA, phone:
(819)376-5075, fax: (819)376-5148
Keywords
11.1 Waste type: Pulp plant effluent
11.2 Process type/waste source: Chemimechanical pulping, Bleaching
11.3 Cleaner Production Technique: Steam Explosion Pulping, Ultra high yield, Vapor phase pulping
process
11.4 Other Keywords: Explosion, Energy, Effluents, Hydrogen peroxide, Paper
11.5 Country Code: Canada.
Assumptions'
Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp plant effluent, Chemimechanical pulping, Bleaching, Steam Explosion Pulping, Ultra high yield,
Vapor phase pulping process, Explosion, Energy, Effluents, Hydrogen peroxide. Paper
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
Headline: Explosion pulping reduces energy consumption in high-yield pulping and produces pulp showing
superior strength properties at a low sulfur content.
SIC/ISIC Code: 13411
Name and Location of Company:
The Swanboard Masonite AB plant at Rundvik, Sweden.
Cleaner Technology Category
Rising electrical power cost has intensified the search for power reduction methods for high-yield pulping.
The explosion method of defibering wood, known since the 1920s, has been used mainly for building board •
manufacture. Renewed interest in this method has been reported for reducing power consumption and
enhancing pulp quality.
5.0 Case Study Summary
1.0
2.0
3.0
4.0
5.1
Process and Waste Information: A modification of the explosion process preimpregnates chips with
sodium carbonate, whereafter the chips are loaded in the gun and SO2 gas is injected to convert
sodium carbonate to sodium sulfite in situ. The released carbon dioxide remains in solution. Upon
heating the chips with high pressure steam (50 bar), pressure builds up within the chips due to CO2
formation. The contents of the gun are then blown to a cyclone kept at 5 bar. This sudden
expansion of steam and CO2 tears up the chips and produces a coarse fiber. The released steam
is condensed in a reboiler to produce 4 bar of fresh steam.
Wood chips were put in an open container and presteamed for 15 min. The container was filled
with cold impregnation liquor, and the chips were covered completely. The impregnation time was
10 min and the liquor was a sodium sulfite solution. The chelating agent DTPA was added to the
liquor (0.5% on bone-dry wood). This DTPA (Kelatex 80) contained 1-5% sodium hydroxide,
which resulted in a pH in the impregnation liquor of approximately 11.0.
After impregnation the pressure vessel was filled up with the chips. The amount of the chips in
the vessel was 42 kg. The time in the vessel was divided into three sequences: degassing,
steaming, and retention time before blowing.
Steam was introduced to heat the raw material and evacuate air. The pressure was raised to 5 bar
(160°C) and kept at this temperature for 10 s.
After degassing, the steam pressure was raised to 30 bar instantaneously and maintained at this
pressure for 30 s.
In the last sequence the pressure was raised to 50 bar and maintained at this level for 5, 15, or 30
s, depending on the sodium sulfite charges, 3.6%, 8.7%, and 14.8% on bone-dry wood
respectively. The valve in the bottom of the vessel was then quickly opened and the chips blown
out.
A sample of coarse fiber from each batch was refined in three or four stages to reach different CSF
levels. Reference CTMPs were produced from the same raw material (spruce).
2-237
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5.2
5.3
5.4
5.5
To estimate energy consumption, the pulps produced by explosion and refining and a reference pulp
were beaten in a PFI-refiner. The pulps were beaten at 10% consistency and then hot disintegrated
and tested for freeness (CSF).
Power consumption in a refiner and the PFI-mill revolutions are not exactly comparable. However,
in absence of better methods this comparison is made to obtain an idea of the order of magnitude
of power consumption. Conventional CTMP requires approximately 1600 kWh/ton when refined
to 400 CSF. By explosion pulping, power can be reduced to 300-600 kWh/t.
Scale of Operation: Pilot-plant tests were conducted. Approximately 300 1 of chips (45 kg) were
the raw material to be pulped.
Stage of Development: These pilot-plant experiments were conducted to verify the feasibility of
this process. The process merits further systematic investigation in pilot scale and testing of the
pulp in papennaking. Further work is in progress to generate sodium sulfide in situ and more
accurately estimate power consumption.
Level of Commercialization:
Material/Energy Balances and Substitutions:
Quantity After
N/A
N/A
N/A
N/A
Material Category Quantity Before
Waste Generation: N/A
Feedstock Use: N/A
Water Use: N/A . .
Energy Use: N/A
6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
Pilot-plant test of spruce by chemical impregnation with sodium sulfite and steam explosion can produce
a pulp with properties superior to CTMP. Electrical energy savings of 25 % are possible. The sulfur
content of the pulp is low.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article.
10.2 Citation: (1) Chaudhuri, P.B., Explosion pulping - exploratory trials, Tappi Journal, December
1989, pp. 196-200
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10.3 Level of Detail of the Source Material: Additional information on pulp properties and pulping
conditions is available in the source material.
10.4 Industry/Program Contact and Address: Mrs Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205,
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf
10.5 Abstractor Name and Address: Same as in 10.4.
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: CTMP, Sulfite impregnation, High yield pulping
11.3 Cleaner Production Technique: Explosion pulping, Energy saving
11.4 Other Keywords:
11.5 Country Code: Sweden.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: CTMP, Sulfite impregnation, High yield pulping, Explosion pulping, Energy saving
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Development of a chlorine-free bleaching sequence of eucalypt kraft pulp.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Aracruz Cellulose Technology Center, Caixa Postal 46, 29 190 Aracruz, ES, Brazil
4.0 Cleaner Technology Category
Pulp mills are improving the effluent treatment facilities and introducing process modifications to meet new
chlorinated organics discharge limits. There is a clear trend to avoid the use of any chlorine compound in
the bleaching the pulp.
This research work contains some preliminary results in the development of a chlorine-free bleaching
sequence of eucalypt kraft pulp. The study was developed around a sequence involving only oxygen and
hydrogen peroxide, and a key intermediary acid treatment.
5.0 Case Study Summary
5.1 Process and Waste Information: The chlorine-free bleaching sequence of eucalypt kraft pulp
involves oxygen pre-bleaching, a patented acid pulp treatment, followed by an oxidative extraction
stage with oxygen and hydrogen peroxide, and peroxide stages. An alternative bleaching sequence
with ozone was also evaluated, and all results were compared with those obtained with the
conventional chlorine-containing bleaching sequence. The alternative sequences were conducted
aiming at 80% + ISO brightness.
Bleaching was performed on a kappa 20 eucalypt kraft pulp. Chlorination, oxygen and oxidative
extraction stages were run in a QUANTUM MARK III high intensity mixer/reactor, while peroxide
and chlorine dioxide stages were performed in plastic bags, at constant temperature. The ozone
treatment was done in a plug flow reactor.
The results so far obtained are quite satisfactory. When starting from kappa 20 pulp, the alternative
sequences produced pulps with brightness in the range of 80% ISO, with lower extractives and
pentosans contents, acceptable brightness .reversion but significantly changed paper properties
relatively to a reference chlorine-bleached pulp.
The proposed sequence is OA(E+P+O)PPr where A stands for a key acid treatment, aimed at
removal of metals from pulp, and increasing its reactivity in the following bleaching stages. HC1,
SO2, HNOZ/NO2, and peracetic acid were studied as acid treatments, and the most promising results
were found for HC1 and peracetic acid.
Ozone was included as an alternative acid treatment, although also with a bleaching action. The
results were quite different from obtained with acid treatment only, and comprise a separate line
of development.
5.2 Scale of Operation: Full scale trials (500 air dry metric tons/day) in 1991 have led to
implementation of a 760 air dry metric tons/day operation, with even better results.
5.3 Stage of Development: Fully implemented.
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5.4 Level of Commercialization: The technology will be available to international market in November,
1992.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use: (low
pressure steam)
Quantity Before
confidential
confidential
confidential
326-817 kg/AD
Quantity After
confidential
confidential
confidential
(depending on
sequence)
6.0 Economics* (items below are not to be disclosed at this time)
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
The results demonstrated the significant influence of acid treatments on metal removal and upon
improvements in pulp reactivity in the additional alkaline stages. The brightness targets were achieved with
extremely high chemicals consumption, and significant effects on pulp quality. Further improvements from
optimization of the acid treatment and peroxide usage, combined with slight modifications in the pulping
process have been achieved in industrial practice. >
8.0 Obstacles, Problems and/or Known Constraints
There is still much to be studied and optimized, especially with regard to (E + P+O) bleaching, and the
acid treatment conditions. Further combinations of such techniques and new developments in pulping,
aiming at higher selectivity, should provide more opportunities for additional improvements in pulp quality,
as well as savings in production costs. Some improvements are already observed, and this is part of a
continuous development programme.
9.0 Date Case Study Was Performed: The results were presented in 1990.
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings.
10.2 Citation: Lima, M.M. de, Manfredi, V. and Claudio-da-SilvaJr, E., Total chlorine-free bleaching
of eucalypt kraft pulp, Tappi Proceedings, 1990 Pulping Conference, pp. 799-807.
10.3 Level of Detail of the Source Material: Additional information on bleaching chemical consumption,
bleaching conditions, pulp and paper properties is available.
10.4 Industry/Program Contact and Address: Claudio-da-SilvaJr, E., General Manager, Technology,
Aracruz Celulose S.A., Caixa Postal 46, 29 190 - Aracruz, ES, Brazil.
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-------
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O. Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Bleach plant effluent
11.2 Process type/waste source: Kraft pulp bleaching, Eucalypt kraft pulp bleaching
11.3 Cleaner Production Technique: Chlorine-free bleaching, Acid treatment, Oxygen bleaching,
Hydrogen peroxide bleaching
11.4 Other Keywords: Ozone, Nitrogen dioxide, Peracetic acid, Hydrochloric Acid, Sulphur dioxide,
Oxygen, Hydrogen peroxide
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Kraft pulp bleaching, Eucalypt kraft pulp bleaching, Chlorine-free bleaching, Acid
treatment, Oxygen bleaching, Hydrogen peroxide bleaching, Ozone, Nitrogen dioxide, Peracetic acid, Hydrochloric
Acid, Sulphur dioxide, Oxygen, Hydrogen peroxide
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Lignox process produces pulp without chlorine or chlorine dioxide while eliminating AOX
in effluent.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The Aspa mill, Munksjo Concern, Sverige.
4.0 Cleaner Technology Category
The Lignox process, a high-temperature peroxide bleaching process for lower-brightness pulp prebleaching,
produces lower-brightness pulp of ISO 70 totally without elemental chlorine or chlorine dioxide. The AOX
content of the effluent is totally eliminated.
5.0 Case Study Summary
5.1 Process and Waste Information: The bleaching is done in three stages after pulping in the Lignox
process. The pulp has a kappa no of 32 after pulping and is then oxygen bleached. Delignification
is further going on, and the lignin content is lowered by about 40%. The kappa number is 18 after
the oxygen stage.
The pulp will next be treated with a so called complex building agent, EDTA (ethylenediamine
tetra-acetic acid). The treatment is done instead of a conventional C/D-stage. The EDTA-treatment
does not change the kappa number of the pulp.
The last stage of die bleaching is an extraction with hydrogen peroxide. A kappa number under
10 can be reached. The process conditions are highly alkaline, and consequently, a SO2 treatment
is needed to reach the right pH level before drying.
The most important point of the Lignox process is to implement the EDTA treatment in the right
and narrow pH area.
5.2 Scale of Operation: The Lignox process has been implemented in full scale. The Aspa mill
produces 120,000 tons pulp/year.
5.3 Stage of Development: The Lignox process has been fully implemented.
5.4 Level of Commercialization: The Lignox process is commercially available.
5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before Quantity After
Waste Generation:
AOX 100 0
COD 100 60-70
Feedstock Use: N/A N/A
Water Use: 100 100
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Energy Use:
100
105-110
6.0 Economics*
6.1 Investment Costs: When changing to Lignox pulp the needed investments in Aspa have been piping
and lining of some bleaching towers. The necessary oxygen delignification and other bleaching
components were already installed.
6.2 Operational and Maintenance Costs: Chemical costs have increased about 100 SEK/ton (Swedish
crowns, 1991) compared to the chlorine bleached pulp.
Maintenance costs have been nearly the same, but in the long run these will possibly be decreased.
Energy costs have, as mentioned in section 5.5, increased.
6.3 Payback Time:
7.0 Cleaner Production Benefits
The Lignox process produces lower-brightness pulp without AOX emissions.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: The process development was done during 1988-90.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article.
10.2 Citation: Forsstrom, A., Aspa Bruk: Forst med klorfri sulfatmassa, Svensk Papperstidning/Nordisk
Cellulosa, Nr 3, 1992, pp. 20-21
10.3 Level of Detail of the Source Material: Additional detail information is not available in the source
material.
10.4 Industry/Program Contact and Address: Hans Fasten, chief of the mill and Sam Wiklund, marke-
ting director, Aspa Bruk, Munksjo koncern, 690 40 ASPABRUK, Sverige, fax: 46 583 504 55,
phone: 46 583 50200.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O. Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Bleach plant effluent
11.2 Process type/waste source: Bleaching
11.3 Cleaner Production Technique: Peroxide bleaching, Lignox process
11.4 Other Keywords:
11.5 Country Code: Sweden.
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12.0 Assumptions
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Bleaching, Peroxide bleaching, Lignox process
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Effluent-free bleach plant in kraft pulp mills.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Jaakko Poyry Oy, P.O.Box 4, SF-O1621 VANTAA, Finland, phone +358-0-89471
4.0 Cleaner Technology Category
Recycling of process water and mineralizing of waste material.
5.0 Case Study Summary
5.1 Process and Waste Information:
Process area: Kraft pulp mill bleach plant
Waste streams affected: Bleach plant waste liquors containing dissolved organic material, .heavy me-
tals, nutrients, and sodium used for bleaching purposes.
Process changes: No changes necessary in the bleaching process; however, economic considerations
lead to equipment modifications and amendments.
Effect on wastes: Waste liquor discharges are eliminated, no AOX discharge, discharge of phosphor
virtually eliminated, heavy metals captured from the discharge and transferred into a low-volume
solid waste.
Production rate: Full scale application.
New waste stream: Low-volume solid waste as indicated above.
New raw materials: None.
Energy usage: Energy balance calculated case by case. Generally, no change in energy
consumption.
Operating procedures:
' The contaminated acidic wastewater is separated into a sufficiently small stream for immediate
treatment in the bleach plant. The alkaline bleach plant waste liquor is used countercurrently as
wash liquor for the oxygen delignified and unbleached pulp. The alkaline wastewater is recirculated
into the chemicals recovery system.
The purification of the acid wastewater is done by evaporation in a specially designed evaporator
utilizing vapour recompression. In principle, the device is a conventional falling-film evaporator.
It operates at low pressure, typically corresponding to the steam pressure of boiling water at 40-
50°C. A single-stage centrifugal fan can be used for vapour recompression.
The concentrate from the evaporator contains mainly hydrochloric acid, but also some organic
matter. Moreover, it contains metal ions and phosphorus and nitrous compounds. The way to
dispose this material is to incinerate the concentrate from the evaporator in controlled conditions
2-246
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6.0
and to mineralise the non-combustible material into inert ash. The heavy metals content of the ash
determines whether it could be dumped as landfill or should be treated in some other way.
5.2 Scale of Operation: Full-scale kraft mills have an annual output of 200,000-1,000,000 tons of pulp.
Total annual world production of bleached kraft pulp is about 60 million tons. Today, all mills
discharge their bleach plant waste liquors through external waste water treatment plants into lakes,
rivers and the sea. This process makes it possible to eliminate this discharge.
5.3 Stage of Development: Pilot stage.
5.4 Level of Commercialization: The technology is not yet ready for commercialization. The
equipment is available from other applications. The evaporator is commercial for seawater
desalination.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
Economics*
6.1 Investment Costs: Large-scale economic figures are not available.
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
The discharge of the bleach plant waste liquor is the single remaining major pollution problem of kraft pulp
mills. Recent development efforts have been focused on the elimination of chlorinated substances in the
mill effluents. Closing up the bleach plant process water system would not only solve this problem, but
eliminate the total discharge of organic material, of nutrients, currently non-recoverable sodium and colored
substances as well.
The driving force for this development work is primarily environmental considerations. However, the
technology would reduce the consumption of fresh water, and sodium now used as a once-through chemical
in the bleach plant would be recirculated and reused. Thus there are economic incentives as well.
8.0 Obstacles, Problems and/or Known Constraints
The technical constraints that may emerge are on the material side; the environment is highly corrosive.
Therefor a long-term test of the special evaporator is under way. No regulatory barriers can be anticipated,
on the contrary, this technology may be classed as "best available technology economically achievable" and
thus favoured for new mills and rebuilds of old mills.
9.0 Date Case Study Was Performed:
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10.0 Contacts and Citation
10.1 Type of Source Material: Organization report and personal contact.
10,2 Citation: Myreen, B., Closing up the bleach plant, Jaakko Poyry Client Magazine," Know-how
Wire", 1/1991, pp. 8-11
10.3 Level of Detail of the Source Material: Professor Bertel Myreen, Jaakko Poyry Oy, P.O. Box 4,
SF-01621 VANTAA, Finland, phone +358-0-89471
10.4 Industry/Program Contact and Address: Professor Bertel Myreen, Jaakko Poyry Oy, P.O.Box 4,
SF-01621 VANTAA, Finland.
10.5 Abstractor Name and Address: Bertel Myreen, Jaakko Poyry Oy, P.O.Box 4, SF-01621
VANTAA, .Finland, phone +358-0-89471
11.0 Keywords
11.1 Waste type: Bleach plant waste liquors, Organic material, Heavy metals, Nutrients, Sodium
11.2 Process type/waste source: Bleach plant, Kraft pulp bleaching
11.3 Cleaner Production Technique: Closed cycle mill
11.4 Other Keywords:
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant waste liquors, Organic material, Heavy metals, Nutrients, Sodium, Bleach plant, Kraft
pulp bleaching, Closed cycle mill
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The NCC-bleaching process uses oxidizing agents in place of chlorine compounds in pulp
bleaching and allows savings in chlorine chemicals and low AOX discharge levels.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Metsa-Serla Oy, Aanekoski pulp mill, and Metsa-Botnia Oy, Kaskinen and Kemi mills, all in Finland.
4.0 Cleaner Technology Category
The inclusion of oxygen, peroxide, ozone and enzyme treatment is a step towards a bleaching process that
has excellent performance and results in very low AOX levels in the bleaching discharge. Chlorine-free
bleaching is the first step towards a substantial reduction in the amount of water used in pulp production.
5.0 Case Study Summary
5.1
5.2
Process and Waste Information: Although cooking to very low kappa numbers can be done the
final yield is always affected. However, cooking to residual lignin content of 2-4% followed by
optimized oxygen delignification to the target kappa number gives pulps with good initial strength
properties and bleachability.
Under alkaline cooking conditions, xylan dissolves from the wood into the cooking liquor. Some
of this xylan has been shown to precipitate back onto the surface of cellulose fibrils. This xylan
is not easily broken down by either hot or cold alkali and therefore hinders the alkaline leaching
of lignin from fibres.
The enzyme xylanase hydrolyses the precipitated xylan, at the same time making the fibres more
permeable and. assisting extraction of lignin. However, enzymes are not bleaching agents; they
merely render alkaline bleaching stages more effective. The critical parameters in enzyme
treatment are: selecting the right xylanase product; the conditions and the location of this step in
the process and the enzyme dosage.
The following sequences have been recommended for bleaching:
Birch: O-e-A-P-P and
Pine: O-e-A-Z-e-P where
e means enzyme treatment and A means acidification + EDTA/DTPA treatment.
Several test runs have been conducted. The process is based on extended cooking and extended
multi-stage oxygen-enzyme-peroxide treatment.
After the last sequence, peroxide bleaching, softwood pulp has reached a brightness of 75-80% ISO
and birch pulp 80-85% ISO. The pulp properties are close to those of normal chlorine bleached
pulps, except for brightness. Brightness stability is not comparable to that of fully bleached pulp,
because of the residual lignin present in the pulp.
Scale of Operation: The successful experience of enzymatic bleaching at Metsa-Serla's Aanekoski
mill was applied together with oxygen and peroxide chemicals at Metsa-Botnia's Kaskinen and Kemi
mills.
Tests on the use of enzyme pretreatment were completed in 1990, and this technology is now in
industrial use. Most recently, in 1991, smaller mill-scale trials were conducted with the aim of
bleaching kraft pulp entirely without chlorine or chlorine compounds. To date, almost 50,000 tons
2-249
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6.0
of both pine and birch pulps have been produced in this way, and Metsa-Serla plans to produce a
further 80,000 tons this year (1992).
Metsa-Botnia is now able to produce chlorine-free softwood and hardwood pulps according to the
demand at its mills at Kaskinen and Kemi. These mills have a total production capacity of 400 000
t/a of chlorine chemical free pulp grades.
5.3 Stage of Development: The technology is fully implemented.
5 4 Level of Commercialization: The technology is commercially available and the equipment needed
is readily available. The enzymes were specifically developed for biological bleaching. Since
September 1991 a rapid commercialization of various paper products produced of chlorine chemical
free softwood and hardwood pulp has taken place.
5.5 Material/Energy Balances and Substitutions: Enzyme application
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use: water
going to the
evaporation plant (see
8.0)
Quantity Before
N/A
N/A
N/A
8 m3/t pulp
Quantity After
15% less total
chlorine AOX
1.0 kg/t pulp
N/A
15-20 m3/t pulp
Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs: The manufacturing costs are somewhat higher than those of
conventional pulp. With 20% chlorine dioxide substitution the cost of bleaching chemicals is 10-
15% higher than for conventional bleaching.
6.3 Payback Time:
7.0 Cleaner Production Benefits
Chlorine-free bleaching is the first step towards a substantial reduction in the amount of water used in pulp
production. The most significant effect of NCC-bleaching has been to reduce bleaching plant discharge
parameters, particularly organochlorine compounds .(AOX).
8.0 Obstacles, Problems and/or Known Constraints
All stages mentioned in 5.1 can be carried out at medium consistency. As no chlorine chemicals are used,
it should be possible to lead all white water from bleaching into the recovery system. However, at a
normal kraft mill, this would increase the volume of water going to the evaporation plant from 8 m3/t pulp
to 15-20 m3/t pulp. This poses new problems for both the recovery cycle and the white water circulation.
Further, if it were possible to raise the working range of the enzymes from the current level of below 55 °C
(and slightly acid conditions) to a 70-80°C range (and alkaline conditions), it would then be possible to
send the dissolved hemicelluloses to the recovery cycle instead of to the effluent treatment. In addition,
intermediate cooling of the pulp would no longer be required.
2-250
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9.0
10.0
11.0
12.0
Date Case Study Was Performed: The foundations for the chlorine-free bleaching of pulp were laid back
in the 1970s when development work in oxygen delignification, peroxide and biological bleaching were
initiated. Six years ago VTT's (Technical Research Centre of Finland) Biotechnical Laboratory and the
Furnish Pulp and Paper Research Institute (FPPRI) started a joint research project on biological bleaching.
The mills of Metsa-Serla and Metsa-Botnia have been investigating the NCC-bleaching for a number of
years. The processes have been commercialized in 1991 (oxygen and peroxide bleaching) and 1992
(enzymatic bleaching). 6
Contacts and Citation
10.1 Type of Source Material: Journal articles and unpublished material.
10.2 Citation:
(1) Trotter, P.C., Biotechnology in the pulp and paper industry: a review, Part 1: tree improvement
pulping and bleaching, and dissolving pulp applications, Tappi Journal, April 1990, pp. 198-204;
(2) Grant, R., Enzyme technology - First mill-scale trials get underway, PPI, June 1991, pp. 61-63;
(3) Breakthrough in pulp bleaching - Completely chlorine-free pulp from Finland, Views on Finnish
technology, Technology development centre Finland, 1992, p. 16;
(4) NCC - non chlorine compound, Metsi-Botnia Oy brochure;
(5) Kekki, R., Chlorine-free bleaching: Technology and mill experience, Environmental technology from
Finland for the Canadian forest industry, Vancouver, March 17, 1992, pp. 65-82;
(6) Malinen R., Chlorine-free bleaching: State of the art in Scandinavia, , Environmental technology from
Finland tor the Canadian forest industry, Vancouver, March 17, 1992, pp. 8-18.
10.3 Level of Detail of the Source Material: Information on paper properties is available in the source
material.
10.4 Industry/Program Contact and Address: Mrs Virve Tulenheimo, MSc, Research Engineer
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P O Box 205*
SF-02151.Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf
10.5 Abstractor Name and Address: Same as in 10.4.
Keywords
11.1 Waste type: Bleach plant waste water
11.2 Process type/waste source: Pulp bleaching
11.3 Cleaner Production Technique: Chlorine-free bleaching, Non chlorine compound bleaching
Enzymatic bleaching, Biobleaching
11.4 Other Keywords:
11.5 Country Code: Finland.
Assumptions
2-251
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13.0 Peer Review
Yes (articles 1. and 2.), others unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant waste water, Pulp bleaching, Chlorine-free bleaching, Non chlorine compound bleaching,
Enzymatic bleaching, Biobleaching
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
Headline: The OxO prebleaching process yields a fully bleached pulp with a substantial decrease in AOX
emissions.
SIC/ISIC Code: 13411
Name and Location of Company:
The Centre Technique du Papier, BP 7110, 38020 Grenoble, Cedex, France.
Cleaner Technology Category
With the optimized (OxO)DED sequence a fully bleached pulp was obtained. This process leads to a
substantial decrease in the AOX (absorbable organic halogens) emission.
5.0 Case Study Summary
1.0
2.0
3.0
4.0
5.1
5.2
Process and Waste Information: It has been found that the use of Cl2 or CIO2 can improve the
selectivity of lignin removal in oxygen bleaching. Since the effluent from the O2 stage is usually
recycled, the logical way to benefit from this activation is to apply it on an oxygen-bleached pulp
to avoid introducing chlorides in the recovery system. This procedure leads to the OxO
prebleaching sequence.
The OxO prebleaching sequence, where "x" stands for the activation treatment with halogens
(chlorine, chlorine dioxide, or a mixture of both) is an oxygen delignification process, which leads
to a high-brightness softwood kraft pulp with low AOX emissions. The OxO process was first
optimized in the laboratory. The process is mainly characterized by the combination of low charges
of chlorine and the use of harsh conditions in the subsequent oxygen stage. This concept could
easily be retrofitted in a mill having an O(C+D)(EO)DED sequence. In an example, a softwood
kraft pulp already oxygen-delignified to kappa no. 20 is submitted to a regular (C+D)(EO)DED
bleaching sequence. The kappa number after O(C+D)(EO) is 1.6 and final brightness is 88.8.
The OxO concept has been applied in preparing this pulp. The results indicate:
• The chlorine multiple can be lowered to 0.15 while increasing the (EO) temperature from 65°C
• The process is sensitive to (EO) temperature.
• Chlorine is a better activation agent than chlorine dioxide.
The results show that using the best conditions, less than 2 kg/ton of TOC1 could be reached No
clear evidence of a decrease in pulp strength or brightness could be noticed. These good results
encouraged to check this process in a full-scale trial.
Plant trials were successful in confirming laboratory results. By running the (EO) stage in harder
conditions, it has been possible to reduce the chlorine multiple down to 0.10 without impairing pulp
characteristics. This process is a possible alternative in environmental control in that 1.5 kg/ton
of AOX (before external treatment) was reached.
Scale of Operation: The full-scale tests of the OxO process were implemented in two mills. The
capacity of one was 500 metric tons/day of softwood kraft pulp for internal use, the other mill
produced 360 tons /day of softwood kraft pulp (market pulp).
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5.3 Stage of Development: The technology was fully implemented and the quantitative figures were
based on actual production.
5.4 Level of Commercialization: The OxO technology is commercially available. The equipment are
readily available, extra equipment are not necessary.
5.5 Material/Energy Balances and Substitutions:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
1.5 kg AOX/ton
N/A
N/A
N/A
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
6.0 Economics*
6.1 Investment Costs: Extra investments are not necessary.
6.2 Operational and Maintenance Costs: Taking into account steam and chemicals, costs increased by
25% from 130 SEK/ton (Swedish crowns) for the reference to 160-165 SEK/ton. Steam costs
accounted for 40% of this increase. The addition of H2©2, although helpful in reducing kappa
number, brought another 10% cost increase and was difficult to justify economically.
6.3 Payback Time:
7.0 Cleaner Production Benefits
With the optimized prebleaching sequence, it was possible to produce high-brightness softwood kraft pulp
with AOX emission as low as 1.5 kg/ton before effluent treatment. A substantial decrease in effluent color
was detected. The pulp viscosity and strength remained constant. Final brightness remained at a high level
throughout the: trial.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: The tests were run in 1989-1990?
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article.
10.2 Citation: Muguet, M., Joly, P., Lachenal, D. and Bohman, G., Mill-scale implementation of the
recycled oxygen process, Tappi Journal, December 1990, pp. 127-132
10.3 Level of Detail of the Source Material: Detail information on bleaching sequences as well as on
pulp properties is available in the source material.
10.4 Industry/Program Contact and Address: Christian de Choudens, Centre Technique du Papier,
Domaine Universitaire, B.P.251, 38044 Grenoble Cedex 9, France, tel: 76 44 82 36, fax: 76 44
7138.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
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11.0 Keywords
11.1 Waste type: Bleach plant effluent, AOX
11.2 Process type/waste source: Bleaching, Kraft bleaching, Oxygen delignification
11.3 Cleaner Production Technique: Recycled oxygen process, OxO process, Oxygen prebleaching
11.4 Other Keywords:
11.5 Country Code: France.
12.0 Assumptions
13.0 Peer Review
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, AOX, Bleaching, Kraft bleaching, Oxygen delignification. Recycled oxygen
process, OxO process, Oxygen prebleaching
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: A short sequence delignification and bleaching process for dissolving pulps from mixed tropical
hardwoods has potential for cost reduction, quality improvement and mill-adaptability as compared to the
present C E H E D sequence.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Pilot Plant Study: The Research Institute of Grasim Industries Ltd, Kumarapatnam 581 123, Kamataka,
India.
Plant Scale: Harihar Polyfibers, Kumarapatnam 581 123, Kamataka, India.
4.0 Cleaner Technology Category
The short sequence E/O C E/O D has potential for cost reduction, quality improvement and mill-
adaptability as compared to the present C E H E D sequence. By proper use of this sequence, it is possible
to achieve 40-60% reduction in COD and BOD and 65-75% reduction in colour of the combined load of
wash and bleach effluents.
5.0 Case Study Summary
5.1 Process and Waste Information: In view of the advantages of oxygen delignification technique with
respect to effluent load reduction and bleaching cost savings, an investigation was carried out.
Various sequences were studied employing oxygen and oxidative extraction stages in the following
combinations: O H E D, C E/O H D, E/O C E/O H D, E/O C E/O D.
Since medium consistency oxygen systems are believed to offer more selective delignification
reactions, as well as ease of retrofitting in existing mill installation with small capital investment,
it was further decided to keep pulp consistency at 8 % and the reaction pressure not in excess of 3.5
kg/cm2 for all the trials. A parallel run with C E H E D sequence was also carried out simulating
plant conditions for comparison.
A number of trials were conducted on mill unbleached pulp for each of the above sequences by
varying the chemical charges, time and temperature to match the brightness and viscosity level with
conventional C E H E D sequence.
The E/O C E/O D, while being a short sequence not only gave the desired final pulp brightness
(89 % ISO) within acceptable viscosity range (14 cP), but also the additional advantage of significant
effluent load reduction. Final adjustment of viscosity could be done by varying the alkali charge
in the E/O-2 stage.
The analysis of oxygen bleached Icraft dissolving pulp from an admixture of Eucalyptus and mixed
tropical hardwoods is superior to both mill and laboratory bleached pulps obtained with conventional
C E H E D sequence except for the high ash components.
5.2 Scale of Operation: The E/O C E/O D short sequence study was on pilot plant scale, whereas C
E/O H D sequence was adopted for mill scale in 1980. The mill experience after installing E/O
stage is as under:
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The C E/O H D was adopted for mill scale operation in view of low investment and easy
adaptability. The E/O stage was introduced in May 1990, and since then, it is running
continuously.
5.3 Stage of Development: E/O C E/O D - Laboratory Scale; C E/O H D - Plant Scale
5.4 Level of Commercialization: E/O C E/O D - Not commercialized; C E/O H D - Commercialized
5.5 Material/Energy Balances and Substitutions:
Quantity Before
CEHED
12 000 m3/day
16.12 t/day
4.40 t/day
35.55 t/day
N/A
N/A
N/A
Material Category
Waste Generation:
COD
BOD
colour
Feedstock Use:
Water Use:
Energy Use:
6.0 Economics*
. 6.1 Investment Costs (May 1990):
Summary of investment
6.1.1 MC Pump with vacuum pump
by Kamyr (imported)
Capacity - 20 Ips.
Cy - 12%
Kead - 75 M
6.1.2 Boughtout & Manufacture items
Stand pipe
Size - 1900 mm dia x 16,500 mm Ht.
Material of construction -
MS & SS 316 lined
6.1.3 Electrical
6.1.4 Instrument
6.1 5 Civil & Misc.
6.1.6 Total
6.1.7 Current Value
Quantity After
C E/O H D
12 000 m3/day
12.0 t/day
4.32 t/day
24.00 t/day
N/A
N/A
N/A
Rs. in Lacs.
29.00
11.90
2.50
2.75
0.90
47.05
64.00
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6.2 Operational and Maintenance Costs:
6.2.1 Savings in Chemicals
a)
b)
c)
Caustic
Chlorine
Chlorate
Per ton pulp
tons
4kg
5kg
0.5kg
Per year
Rs. Lacs
37.05
8.35
5.72
6.2.2 Recurring Costs
a) Oxygen
b) Power
c) Manpower
d) Maintenance Cost
6.2.3 Net Savings per Annum: Rs. 17.83 lacs
Total Savings 49.12
4.5kg
5.5 kWh
4 operators
Total Cost
23.73
5.44
1.32
0.80
31.29
6.3 Payback Time: Investment Rs. 64 lacs, Savings Rs.17.83 lacs, Pay Back Period 64/17.83 = 3.6
Years
7.0 Cleaner Production Benefits
As compared to the conventional C E H E D sequence such bleaching process offers following advantages:
1. Reduced chemical cost
2. Substantial reduction in effluent load
3. Ease and retrofitting in the existing mill installations with small investment
4. Improved pulp quality in terms of brightness, degree of polymerisation (D.P.) distribution and
better processability in fibre plant
8.0 Obstacles, Problems and/or Known Constraints
No technical constraints.
9.0 Date Case Study Was Performed: May 1990.
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings, Mill experience.
10.2 Citation: Jain, S.K. and Maru, S.S., A short sequence delignification and bleaching process for
dissolving pulps from mixed tropical hardwoods, Tappi proceedings, International Oxygen
Delignification Conference, 1987, pp. 75-80.
10.3 Level of Detail of the Source Material: Additional information on bleaching conditions and pulp
analysis is available in the source material.
10.4 Industry/Program Contact and Address: S.S. Maru, Joint Executive President (Technical), Harihar
Polyfibers, Kumarapatnam 581 123, Kamataka, India.
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10.5 Abstractor Name and Address: Mrs Virve Tulenheimcf, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Bleach plant effluent
11.2 Process type/waste source: Pulp bleaching
11.3 Cleaner Production Technique: Oxygen delignification, Oxidative extraction
11.4 Other Keywords:
11.5 Country Code: India.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Pulp bleaching, Oxygen delignification, Oxidative extraction
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The Prenox (TM) process, pretreating pulps prior to oxygen-delignification with NO2, reported
to remove a substantial lignin and reduce TOC1 level.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
The Prenox process has been developed by the Swedish companies AGA, KemaNord, MoDo and Sunds
Defibrator.
4.0 Cleaner Technology Category
The Prenox process increases the selectivity of the oxygen toward lignin in the oxygen delignification stage.
The amount of the bleaching chemicals needed is reduced and the environmental effect of the bleach plant
effluent decreased.
5.0 Case Study Summary
5.1 Process and Waste Information: A research effort has been made in order to find ways of
delignification to still lower kappa numbers. Special attention has been paid to the ability of
nitrogen oxides to activate the lignin degradation. In the Prenox process, the softwood pulp can
be treated with nitrogen dioxide in acid conditions prior to oxygen delignification. In laboratory
conditions, it is possible to extend the delignification down to the kappa number 7 without severely
impairing the papermaking properties of the pulp. On a pilot scale, the practical kappa number
limit is about 10.
The tests have been made using a normally cooked softwood pulp with an initial kappa number of
about 30. The test figures show that at low charges (5 and 6 kgs per ton respectively) NO2 is as
efficient as molecular chlorine. At increased concentrations molecular chlorine shows a more
selective delignification.
Laboratory pretreatment tests using already oxygen delignified softwood pulp have also been made.
With a nitrogen dioxide pretreatment at 10% consistency and subsequent delignification in a
pressurized (EO) stage, an acceptable pulp with the kappa number 7 has been obtained.
5.2 Scale of Operation: Pilot plant scale.
5.3 Stage of Development: Pilot stage.
5.4 Level of Commercialization: The Prenox process is not yet commercially available.
5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before Quantity After
Waste Generation: N/A 1.5 kg/t
Feed Stock Use: N/A N/A
Water Use: N/A N/A
Energy Use: N/A N/A
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6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
See 4.0.
8.0 Obstacles, Problems and/or Known Constraints
All effective pretreatments occur in acidic conditions, which is a drawback, because the pulp is alkaline
after the cook.
If nitrous compounds are used, the NOx emissions from the recovery boiler are likely to increase.
Using nitrogen dioxide would pose serious questions related to health and safety at work.
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and an environment report.
10.2 Citation:
(1) Bowen, I.J. and Hsu, J.C.L., Overview of emerging technologies in pulping and bleaching, Tappi
Journal, September 1990, pp. 205-217;
(2) Pride, D., Old pulps for new, Paper, November 990, pp. 26-29;
(3) Ahlgren, L., Kraft pulp: Cleaner still by year 2000, PPI, April 1991, pp. 59-61;
(4) Heimburger, S.A., Blevins, D.S., Bostwick, J.H. and Donnini, G.P., Kraft mill bleach plant effluents:
recent developments aimed at decreasing their environmental impact, part 1, Tappi Journal, October 1988,
pp. 51-60;
(5) Reduction of Chloro-organic Discharge in the Nordic Pulp Industry, Environment Report 1989:6E,
Prepared by Jaakko Poyry for The Nordic Council of Ministers, April 1989, 103 p.
10.3 Level of Detail of the Source Material: Additional information is not available in the source
material.
10.4 Industry/Program Contact and Address: Christian de Choudens, Centre Technique du Papier, Boite
postale 251, F - 38044 Grenoble Cedex 9, France, tel: 76 44 82 36, fax: 76 44 71 38.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
2-261
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11.0 Keywords
11.1 Waste type: Bleach plant effluent
11.2 Process type/waste source: Pulp bleaching
11.3 Cleaner Production Technique: Cleaner Production Technique
11.4 Other Keywords:
11.5 Country Code: France.
12.0 Assumptions
13.0 Peer Review
Yes (1-4 in 10.2) and unknown (5).
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Pulp bleaching, Cleaner Production Technique
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Papricycle bleaching process saves each plant caustic and steam.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Weyerhaeuser Canada Ltd., P.O.Box 800, Kamloops, B.C., Canada V2C 5M7.
4.0 Cleaner Technology Category
One method of lessening the demand for caustic is to ensure that the alkaline streams within the mill are
used efficiently. The Papricycle process makes better use of one of these alkaline streams. The process
provides a savings of 35 % in caustic usage.
Recycling of hot filtrate has the potential to decrease steam usage by 0.43 GJ/ton of pulp.
5.0 Case Study Summary
5.1 Process and Waste Information: The comparison of Hostage procedures, no recycle, conventional
recycle, and recycle followed by washing was done in the laboratory. The results were obtained
with a laboratory-cooked black spruce kraft pulp of kappa no. 27.5. The pulp was chlorinated
conventionally and then thoroughly washed with deionized water.
In the "recycle followed by washing" runs, the chlorinated pulp was brought to 20% consistency
and diluted to 10% consistency with the effluent from a conventional extraction stage. The
extraction effluent, at 60°C, was again allowed to be in contact with the pulp for 5 min. In these
runs, however, the pulp was washed before the conventional extraction stage. Recycle followed by
washing allowed a target kappa number or a target brightness to be obtained with only 2.0 % NaOH
in the El stage, compared to the 3.0% NaOH required to reach the same kappa number or
brightness level in the other examples. This process of El-stage effluent recycle followed by
washing to decrease the chemical requirements in the El stage has been called "Papricycle".
There are several ways in which a bleach plant can be modified to use Papricycle. The simplest
modification is that applied to a mill which has a six-stage bleach plant and which, by adding
oxygen to the extraction stage, has eliminated the hypochlorite stage. As a result of these changes,
the original H-stage washer can be repiped for use as the "Papricycle washer." In effect, it will be
operating as if it were between the C-stage washer and the E-stage steam mixer.
The first full mill application in Canada required the simplest of the available modifications.
5.2 Scale of Operation: The Kamloops mill is divided into two lines; the first of which, referred to as
"A" mill, produces 330 air dry metric tons/day of pulp. The second and larger line, "B" mill,
produces 920 air dry metric tons/day of pulp.
5.3 Stage of Development: Fully implemented.
5.4 Level of Commercialization: The Papricycle process is commercially available. The operation of
the bleach plant is only minimally altered by the introduction of the process.
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6.0
5.5 Material/Energy Balances and Substitutions: Combined mill effluent properties:
Material Category Quantity Before Quantity After
Waste Generation:
274 kg/t
8.8
2.9 kg/t
2.9 kg/t
132 m3/d
GJ/t pulp
colour
clarifier pH
BODS
CaO
Water Use:
Energy Use: steam
244 kg/t
9.7
2.3 kg/t
2.3 kg/t
123 m3/d
saving 0.43
Economics*
6.1 Investment Costs: The total cost of installing the new process was $23,000 (Canadian dollars 1989)
for the "A" mill and $ 2,130,000 for the "B" mill.
6.2 Operational and Maintenance Costs: The chemical cost savings attributed to Papricycle at the
Kamlodps mill are $525,000/year for the "A" mill and $2,830,000/year for the "B" mill.
6.3 Payback Time: The costs in 6.1 and 6.2 represent a savings of $4-5/ton of pulp produced, with
a payback time of 15 days.
7.0 , Cleaner Production Benefits
The process provides a saving of 35 % in caustic usage. Recycling of hot filtrate has the potential to
decrease steam usage by 0.43 GJ/ton of pulp. The bleach plant effluent properties have been improved.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: The first mill scale trial was run during July 1987.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and Conference proceedings.
10.2 Citation: (1) Berry, R.M., Fleming, B.I., Beradt, G. and Williams, G., Papricycle - a mill proven
process for saving bleach plant caustic and steam, Tappi Journal, February 1989, pp. 109-113;
(2) Advances in pulping, Tappi Journal, November 1988, pp. 16-20; (3) Bemdt, G. and Williams,
G., Maintaining the caustic chlorine balance in a bleached kraft pulp mill, CPPA Pacific & Western
Branch Meeting, Jasper, B.C., May 1990, 7 p.
10.3 Level of Detail of the Source Material: Additional information on the changes made in the existing
process and pulp properties is available in the source material.
10.4 Industry/Program Contact and Address: R.M. Berry, scientist and B.I.Fleming, senior scientist,
PAPRICAN, 570 Blvd. St.Jean, Pointe Claire, Que., Canada H9R 3J9. G. Berndt, technical
superintendent and G. Williams, process superintendent, Weyerhaeuser Canada Ltd., P.O.Box 800,
Kamloops, B.C., Canada V2C 5M7.
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10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Bleach plant effluent
11.2 Process type/waste source: Pulp bleaching
11.3 Cleaner Production Technique: Papricycle process, E-stage effluent recycling
11.4 Other Keywords: Caustic, Steam
11.5 Country Code: Canada.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Pulp bleaching, Papricycle process, E-stage effluent recycling, Caustic, Steam
2-265
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The effect of enzyme pre-treatment on the bleachability of kraft pulps.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
Genencor International Europe Ltd, SF-02460 Kantvik, Finland.
4.0 Cleaner Technology Category
Better bleachability means possibilities to use lower amounts of bleaching chemicals, and thus, the AOX
and TOC1 levels are substantially lowered both in the end product and in the bleachplant waste waters.
A lower toxicity of bleachplant effluents will have a long term positive effect on the mill's biological treat-
ment. On the other hand, higher brightness levels can be reached without changing the chlorination factor.
5.0 Case Study Summary
5.1 Process and Waste Information: Albazyme is an enzyme blend specially designed to improve the
bleachability of softwood and hardwood kraft pulps. The performance of Albazyme is a result of
synergistic effects of all the main and side activities and cannot be evaluated only on the basis of
declared activity. The main component is commonly referred to as xyianase activity.
The Albazyme treatment will be ideally performed in the high density brown stock tower under the
following conditions: temperature 40-60°C, pH 5-7, and reaction time 0.5-3 hours. No additional
washing is needed after Albazyme treatment. Acidification of the brown stock can be achieved with
various acids, including C-stage filtrate or CIO2 generator's waste acid.
Albazyme is effective on both conventional and oxygen delignified pulps. Under suggested process
conditions and with appropriate dosage no negative effect on pulp strength or cleanliness will be
noted. Albazyme is compatible with oxygen and peroxide boosted extraction stages.
5.2 Scale of Operation: Mill-scale application.
5.3 Stage of Development: Fully implemented.
5.4 Level of Commercialization: The technology as well as equipment is commercially available.
6.0
5.5 Material/Energy Balances and Substitutions
Material Category Quantity Before
Waste Generation:
Feedstock Use: 100
Water Use: N/A
Energy Use: N/A
Economics
Quantity After
positive effect
75-85
N/A
N/A
6.1 Investment Costs: Albazyme will be used without any major change in the bleachplant. The only
additional equipments needed are a dosage system and a pH control loop.
6.2 Operational and Maintenance Costs: Maintenance cost is about zero. Operational cost varies case
by case, but in most cases it is about the same as the cost savings of chemicals.
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7.0
8.0
9.0
10.0
11.0
13.0
6.3 Payback Time: Short, but varies case by case.
Cleaner Production Benefits
The benefits of using Albazyme as a prebleaching agent are clearly measured in several perspectives.
Lower dosage of Cl2, CIO2, NaOH etc. is needed, leading to savings in chemical cost. Albazyme will be
particularly attractive to pulp mills with regulatory pressure on AOX/TOC1 levels, with limited capital
investment possibilities and with a plan for higher CIO2 substitution level or CIO2 generator capacity
limitations.
Obstacles, Problems and/or Known Constraints
Date Case Study was Performed
Contacts and Citation
10.1 Type of Source Material: A brochure.
10.2 Citation: ALBAZYME, Pulp and Paper enzymes, Biopulp International, brochure, 4 p.
10.3 Level of Detail of the Source Material: Additional information on the enzyme properties is
available in the source material.
10.4 Industry/Program Contact and Address: OHi Jokinen, Product Manager, Pulp & Paper Enzymes,
Genencor International, SF-02460 Kantvik, Finland, phone: +358 0 297 4660, fax: +358 0 298
2203, .telex: 121076 supo sf
10.5 Abstractor Name and Address: OHi Jokinen, Product Manager, Pulp & Paper Enzymes, Genencor
International, SF-02460 Kantvik, Finland, phone: +358 0 297 4660, fax: +358 0 298 2203, telex:
121076 supo sf.
Keywords
11.1 Waste type: Bleach plant effluent.
11.2 Process type/waste source: Kraft pulp bleaching.
11.3 Cleaner Production Technique: Enzyme pretreatment.
11.4 Other Keywords: Albazyme, Kraft pulp.
11.5 Country Code: Finland.
12.0 Assumptions
Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Kraft pulp bleaching, Enzyme pretreatment, Albazyme, Kraft pulp.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The economic effect of enzymatic treatment on kraft pulp bleaching.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
PI Process Consulting Ltd., Myyrmaenraitti 2, P.O.Box 31, SF-016101 Vantaa, Finland, phone +358 0
530 91, telex 122905 pihki sf, telefax +358 0 563 2003.
4.0 Cleaner Technology Category
The enzymatic treatment reduces the need of active chlorine in kraft pulp bleaching and the AOX load of
the effluents will be decreased.
5.0 Case Study Summary
5.1 Process and Waste Information: The investment and operating costs were compared when an
enzyme treatment stage or an oxygen delignification stage was added to a reference process. As
a reference mill, a new mill with annual average production of 400,000 ADt/a (400-mill) and an
old mill with annual average production of 200,000 ADt/a (200-mill) fully bleached kraft pulp were
used.
The operating and investment cost calculations are based on specific consumption values from
material and energy balance calculations using the RAMI simulation program developed by PI
Process Consulting Ltd. The balance calculations cover the whole pulp mill process.
5.2 Scale of Operation: See 5.1. The addition of the enzyme stage to the reference mill causes changes
in the dimensioning of the chlorine dioxide plant and chemical recovery system. The additional
capacity requirement in the chemical recovery line is about 15%. The capacity of the chlorine
dioxide plant can be reduced from 34.5 t/d to 27.5 t/d.
The addition of an oxygen delignification stage to the reference mill causes changes in the chemical
recovery line capacity by about 1.5%. The capacity of the chlorine dioxide plant can be reduced
from 34.5 t/d to 21.0 t/d.
5.3 Stage of Development: The calculations are based on results of a simulation program.
5.4 Level of Commercialization:
5.5 Material/Energy Balances and Substitutions
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
15-25% less AOX
20-30% less active
chlorine in prebleaching
N/A
N/A
Quantity After
N/A
N/A
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6.0' Economics
6.1 Investment Costs: The total investment costs for a Scandinavian kraft pulp mill producing 400,000
ADt/a has been estimated to 2,400 million FIM in spring 1991. The total investment costs for the
mill, including enzyme treatment, are only 0.3 million FIM more expensive than the costs for the
reference mill.
The addition of the oxygen delignification stage makes the total investment costs 5.8% more
expensive than the investment costs for the reference mill.
When an enzyme stage is added to the "old" 200,000 ADt/a mill, the investments are estimated to
cost 1.4 million FIM. The additional cost for the oxygen stage is estimated to be 85.0 million FIM.
6.2 Operational and Maintenance Costs: With present enzyme prices and charges, the operating costs
for the enzyme treatment are 16-17 FIM/ADt higher than the operating costs for the reference mill
(400-mill). Oxygen.delignification gives a clear chemical cost saving.
The inclusion of an enzyme stage or an oxygen stage to the 200-milI causes changes in the operating
costs that are in the same range as for the 400-mill.
6.3 Payback Time:
7.0 Cleaner Production Benefits
See 4.0
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study was Performed: The work was reported in June 1991 and it is a part of SYTYKE, the
Environmental Research and Development Programme for the Finnish Forest Industry.
10.0 Contacts and Citation
10.1 Type of Source Material: A research programme report.
10.2 Citation: Sannholm, G., Pusa, R. and Soderstrom, M., The effect of enzymatic treatment on kraft
pulp bleaching, A SYTYKE research programme report, 65 p. (English abstract only)
10.3 Level of Detail of the Source Material: Additional information on the material balances and more
detailed costs is available in the source material.
10.4 Industry/Program Contact and Address: Gun Sannholm, Project Manager, PI Process Consulting
Ltd., Myyrmaenraitti 2, P.O.Box 31, SF-016101 Vantaa, Finland, phone +358 0 530 91, telex
122905 pihki sf, telefax +358 0 563 2003.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type: Bleach plant effluent.
11.2 Process type/waste source: Kraft pulping, Pulp bleaching.
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11.3 Cleaner Production Technique: Oxygen delignification, Enzyme treatment.
11.4 Other Keywords: Enzymes, Operating costs, Investment costs, Simulation.
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Bleach plant effluent, Kraft pulping, Pulp bleaching, Oxygen delignification, Enzyme treatment,
Enzymes, Operating costs, Investment costs, Simulation.
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***** DOCNO: 400-005-A-196 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
^MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Closed-cycle technology in bleached kraft pulp mill reduces wastewater
generation through materials and recovery substitution and countercurrent
washing.
Manufacture of Pulp, Paper and Paper Board; Bleached Kraft Process/SIC
2611
U.S. Environmental Protection Agency
The company runs a 725 ton/day ERCO Envirotech (Rapson-Reeve)
closed-cycle technology for bleached kraft pulp mills. Chlorine dioxide
replaced 70 percent of the chlorine normally used in the first-stage
chlorination. This stage is followed by conventional caustic extraction,
chlorine dioxide regeneration. Countercurrent washing is employed by the
bleach plant, and bleach plant effluent is re-used in pulp mill in
countercurrent brown-stock washers. Sodium chloride is recovered from
white liquor by evaporation and filtration and is used in chlorine dioxide
generator. Saltcake (sodium sulphate) in chlorine dioxide generator can be
dried and sold. Salt (sodium chloride) from salt removal process can be
re-used in the generation of bleaching chemical such as CIOz, NaOH-Cl2
and NaClO3.
Wood, NaClO3, C12, H2, SO2, NaOH, Lime
Aqueous Na2SO4 and solid sodium sulfate
Low-level contaminated water
(1975 Dollars)
4.5 million
1.0 million
Not reported
Not reported
2.2 million/year
Fresh process water requirement reduced from 104 mVton to about
15m3/ton.
Total flow of 117 m3/ton
Reduced wastewater and wastewater contamination in bleached kraft
process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Closed Cycle Technology for Bleached
Kraft Pulp Mills," Monograph ENV/WP.2/5/Add.5).
Bleached Kraft Pulp, Paper, Wastewater, SIC 2611
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*****DOCNO: 450-003-A-363*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Northwood Pulp and Paper modernizes bleaching system and particulate
removal system and reduces bleaching effluent and particulate emissions.
Paper and Allied Products/SIC 26
Northwood & Paper, Ltd.
Prince George, British Columbia
A 680 ton/day bleached sulfite pulp mill installed equipment supplied by
Kamyr to reduce the volume of effluent. Four separate bleaching stages
occur in a single tower. Bleaching chemicals are displaced through the mat
of pulp as it moves upwards. A Munters particulate removal unit was
installed to reduce particulate emissions from the smelt dissolving stack.
The unit comprises a number of multiangular components arranged in
parallel for form modules that act as mist eliminators through impaction.
The particulates in the gas stream are wetted and captured and the collected
water droplets are directed back down the stack.
Emissions
Bleaching effluent
Air
Munters unit - $40,000 compared to the Venturi unit - $230,000.
Not reported
Not reported
Dollar values not reported.
No energy requirements for the Munters unit, compared to $15,000'/year for
Venturi scrubber, with 90% the removal efficiency.
Bleaching effluent reduced to 15 miVton of pulp, particulate emissions
reduced to 0.2 kg/ton.
Waste management was improved at this pulp mill with the dynamic
bleaching process which reduces effluent, and with the Munters particulate
removal unit which reduces emissions.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 65.
Pulp and Paper, Bleached Kraft Pulp, Scrubber Effluent, Process Change,
SIC 26
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***** DOCNO: 450-003-A-364*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Installation of continuous sulfonated chemi-mechanical pulp (SCMP) plant
and scrubber system reduces paniculate emissions and increases plant
yields.
Paper and Allied Products/SIC 26
Abitibi-Price, Inc.
Fort Williams Division
Thunder Bay, Ontario
A batch sulfite pulp operation was replaced by a continuous sulfonated
chemi-mechanical pulp (SCMP) plant to reduce sulfite effluent. A scrubber
system was installed that contains an alkaline liquid suspension of powdered
activated carbon which trickles downwards through packing, ensuring
gas/liquid contact. Hydrogen suifide is absorbed by the alkaline solution
and then reacts with caustic and oxygen to produce sodium thiosulfate.
Sulfur dioxide is recovered in the form of sodium sulfate, and the scrubbing
liquor is recycled to the scrubber. The gas is then washed and heat is
recovered through direct contact with water.
Wood chips, sodium sulfate
Suifide wastes, emissions
Water, air
SCMP plant - $30 million.
Not reported
36
Dollar values not reported.
Reduced energy consumption.
Scrubber removes 96.4% of the hydrogen suifide and all the sulfur dioxide.
Paniculate emissions reduced from a range of 200-500 jtg/m3 to 126 fig/m3.
The new SCMP process complies with Ontario provincial controls on the
amount of effluent entering Lake Superior. Plant yield has been increased
from 70% to 90%, and paniculate emissions have been reduced by 37-75 %.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 66.
Pulp and Paper, Hydrogen Suifide, Scrubber Effluent, Process Change,
Heat Recovery, SIC 26
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***** DQCNO: 401-006-A-OOO *****
1.0 Headline: Reduction of multimedia wastes in Finnish pulp and paper factories
2.0 SIC Code: 26 Paper and Allied Products, 2611 Pulp Mills, 2621 Paper Mills.
3.0 Name & Location of Company: 53 mill sites located throughout Finland. Mill sites include: Kemi, Oulu,
Kajaani, Jamsankoski and Jamsa, Varkaus, Aanekoski, Tampere area. Southern lake Saimaa and the River
Kymijokl. Examples of mill sites established since 1950 include Kemijarvi in the north, Uimaharju in the
east, Kaskinen in the west and Kirkniemi in the south of Finland.
4.0 Clean Technology Category: This case study provides an overview of waste reduction in Finland's pulp
and paper industry involving environmental legislative action, administration, improved processes and
equipment and recycling.
5.0 Case Study Summary
5.1 Process and Waste Information: The Finnish pulp and paper industry has seen a trend of
replacement of sulfite pulping processes with mechanical and sulfate pulping processes. This trend
coupled with the development of loads and pollution control measures as well as increased
administration and legislation has brought about a promotion of both industrial development and
environmental achievement in the form of multimedia waste reduction.
The development of effluent loads and pollution control measures have lead to decreases in
wastewater discharge quality and volume in Finland for the following reasons: 1. Considerable
structural change in the industry with a shift from sulfite mills to sulfate and mechanical pulp mills;
2. .Improved process internal measures which have lowered chemical losses; including the
improvement of control systems, reduction of water consumption by closing some water circulation
systems; and the improvement of production processes and equipments (i.e., dry debarking,
increasing the recovery rate of spent liquor, stripping of condensates, changes in pulp cooling
systems and changes in bleaching and chemical ad conditions).
Malodorous gases from chemical pulp mills are a problem in Finland. The structural development
of the pulp industry has promoted air pollution control, because sophisticated chemical circulation
systems in sulfate mills have eliminated emissions of sulfur compound. It is expected that as
facilities are modernized total emissions of malodorous sulfur compounds by the pulp industry will
be reduced to 3000-7000 tons per year (Sulfur dioxide emissions in the 1970's totalled about
600,000 tons per year.).
The total quantity of wastes accumulated in .Finland each year attributed to the pulp and paper
industry is approximately 70-80 million tons. (10 million tons are wood wastes and 815,000 tons
are paper and cardboard). Only 35-40% of paper and cardboard are recovered in Finland due to
limited capacity of the paper industry to receive paper from households due to export orientation
and competition on quality. The degree to which wastes are used in the future will depend on the
development of raw material and energy prices. The standard of waste management will depend
on the state of development of utilization technology and methods.
5.2 Scale of Operation: Approximately 53 mills in Finland are subject to and participate in the
combined efforts of the government to reduce wastes and emissions from pulp and paper
manufacture.
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5.3
6.0
5.4
5.5
State of Development: In Finland, environmental legislation and administration has not developed
in parallel. There is a differentiation of the control mechanisms in administration and in
environmental protection in legislation. Finland must make an effort to harmonize the licensing and
notification system. e
Level of Commercialization: All of the strategies discussed have originated in or have been
implemented in the pulp and paper facilities in Finland.
Balances and Substitutions: The industry has trended towards the replacement of sulfite pulping
processes to mechanical or sulfate pulping processes. This trend coupled with tighter discharge
limits and control mechanisms have resulted in a reduction of pollution. In wastewaters, the
suspended solids and biological oxygen demand have decreased in the years 1980-1984 by 23 % and
15% respectively. However, the load of nutrients has increased with the increase in production
Air emissions of sulfur dioxide totalled about 600, 000 tons per year in the 1970s. It is expected
that modernized total emissions of the pulp and paper industry will be reduced to 3000-7000 tons
a year depending on the effectiveness of air pollution control. The installation of a new deinking
facility is expected to increase the capacity of Finland to recover paper and cardboard thereby
reducing the amount of solid wastes generated in Finland (about 300 000 tons per year)
Economics:
6.1
6.2
6.3
Investment Costs: Although costs were not specifically discussed, there was indication that sulfite
mills have been converted to mechanical or sulfate pulping mills for reasons of profit. It was also
stated that the recovery of energy and raw materials brought about by Finland's program is
economically beneficial. p e
Operational and Maintenance Costs: Costs were not discussed. However, it was mentioned that
an industrial plant with sound production costs is also sound from the point of view of
environmental protection. This suggests that the saving of environment, energy, and raw material
nas become a factor that promotes industrial development in Finland.
Payback Time: Environmental benefits are recognized immediately.
specific costs and paybacks were not discussed.
Individual facilities and
7.0 Cleaner Production Benefits
The new sulfate and mechanical pulping processes are more profitable than the older sulfite pulping
processes and also produce lowered air emissions arid improved wastewater quality.
8.0 Obstacles, Problems and/or Known Constraints
Finland has not harmonized licensing and notification systems. This has resulted in a differentiation of the
control mechanisms in administration and in environmental protection in legislation.
9.0
study was performed: This case study was developed from proceedings of the Finland/UNEP
,00* on Sou"d Environmental Management in the Pulp and Paper Industry in Helsinki held
, 19oO.
10.0 Contacts and Citation
10.1 Type of Source Material: Proceedings of the 1986 Finland/UNEP International Seminar on Sound
tnvironmental Management in the Pulp and Paper Industry.
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10.2 Citation: Ruonala, Seppo, "Environmental Mangement in the Finnish Pulp and Paper Industry."
Sound Environmental management in the Pulp and Paper Industry. Seminar Papers and Documents
(May 14-17 1986): 65-75.
10.3 Level of Detail of Source Material: More detailed information on water discharge loads are
available. This document is an overview of improvements in Finland's pulp and paper industry and
does not provide facility specific data.
10.4 Industry/Program Contact and Address: Mr. Seppo Ruonala, National Board of Waters, Finland.
10.5 Abstractor and Address: Susan Wojnarowski, Science Applications International Corporation,
7600-A Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords:
11.1 Waste Type: Sulfur dioxide emissions, Sulfide wastes, Wastewater, Wood fiber, Organic sludges,
Liquors.
11.2 Process Type/Waste Source: Pulping operations, paper manufacture, SIC code 2611, Pulp Mills,
and SIC Code 2621, Paper Mills.
11.3 Waste Reduction Technique: Process redesign, air pollution control, equipment modification,
chemical use review, wastewater reduction, waste segregation.
11.4 Other Keywords: Finland.
Keywords: Equipment Modification, Process Redesign, Pulp and Paper Mills, Sulfur Dioxide Emissions,
Wastewater
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***** DOCNO: 450-003-A-365*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Tembec converts coal fired boiler to use waste sulfite liquor as fuel
substitute.
Paper and Allied Products/SIC 26
Tembec, Inc.
Temiscaming, Quebec
A coal-fired boiler at a pulp mill was converted to use waste sulfite liquor.
The liquor from the batch digesters is taken to a blow-pit, and then drawn
off to a storage tank. Vapor compression evaporators increase the
concentration to 49-50% solids, and the liquor is ready for use in the boiler.
Waste sulfite liquor
Emissions
Air
$32 million
Less than costs of coal-firing boiler
38
$10 million/year.
Reduced costs for fuel.
Improved quality of emissions.
Conversion of a coal-fired furnace to one that burns plant waste reduces
fuel costs by eliminating coal purchases, and reduces hazardous emissions
that are emitted from coal furnaces.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 67.
Pulp and Paper, SIC 26
2-277
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Norwood Pulp and Paper Mills
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The PUNEC pulping process produces bleached pulp from agricultural residue (e.g., bagasse
or rice straw) and selectively separates lignin and hemicellulose with minimal water use and no release of
soluble waste or noxious gas.
2.0 SIC/ISIC Code: 13411,13511
3.0 Name and Location of Company:
Pudumjee Pulp & Paper Mills Ltd., Thergaon, Pune 411 033, India.
4.0 Cleaner Technology Category
The process involves delignification of lignocellulosic material in the absence of environmentally polluting
sulphur and chlorine compounds, using solvent ethanol and oxygen in bleaching, refining lignocellulosics
into pulp, lignin and hemicelluloses. These products form environmentally friendly natural polymers and
animal feeds. The simplicity of pulping makes it possible, to establish mini mills.
5.0 Case Study Summary
5.1 Process and Waste Information: The PUNEC pulping process provides a cleaner production
technique involving use of an ethanol-water mixture as solvent, in presence of catalytic amount of
caustic soda so as to obtain a near neutral pH at the end of the delignification reaction and also
providing as environment for selective removal of lignin with high yield of pulp. The solvent is
recovered by flashing and distillation to recycle the same in the process. Lignin is precipitated in
the form of chocolate brown coloured solids by proper acidification and dilution and amounts to
about 15% of the dry weight of fibre processed. The remaining aqueous extract after the solvent
recovery is rich in hemicelluloses concentrated to a syrup to use it in animal feed.
Thus, the process refines lignocellulosic material into three products named above and lets no
dissolved organic waste or polluting chemicals to environment. Therefore, the objective of
environmentally benign process is truly met with the advent of this pulping process.
Pulp consumes about 30% lower bleaching chemicals and responds well with the chlorine free
bleaching chemicals, such as oxygen and peroxide.
Products or production rates resulting from the applications:
• 172 MT O.D. (oven-dry) deputhed bagasse upon PUNEC pulping process yields 110 MT O.D.
of unbleached pulp of kappa number 30 4- 3, which upon screening and bleaching by OOP
sequence yields 100 MT O.D. bleached pulp at 80+1 % ISO brightness.
• About 26.0 T lignin and an equal amount of hemicellulose concentrate on dry basis are obtained
while the solvent recovery is 99% on the charge.
5.2 Scale of Operation: Tested at pilot plant level producing 15 kg pulp per day at Pudumjee Mills.
5.3 Stage of Development: Pilot plant scale.
5.4 Level of Commercialization: One hundred tonnes per day plant will be established by M/s.
Pudumjee Pulp & Paper Mills by 1994.
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5.5 Material/Energy Balances and Substitutions: See 5.1 and 7.0.
6.0
7.0
8.0
9.0
Material Category Quantity Before Quantity After
Waste Generation: N/A N/A
Feedstock Use: N/A N/A
Water Use: N/A N/A
Energy Use: N/A N/A
Economics*
6.1 Investment Costs: To be established.
6.2 Operational and Maintenance Costs: To be established.
6.3 Payback Time: To be established.
Cleaner Production Benefits
The PUNEC pulping process has the following benefits:
• the process invites conservation of raw materials by producing higher yields of pulp.
• the process also provides means of recovering the chemicals used therein and their reuse in the process
thereby economizing the method of delignification of agricultural residues.
• the solvent used in the process is a renevable organic material benign to the environment.
• the recovery of useful by-products such as lignin and hemicelluloses, which are normally lost to the
effluent, makes the process to operate at lower cost.
• no generation of AOX and process is free from TRS and lime grits.
• requires far less water than conventional pulping.
• lower capital cost than in the conventional pulping.
Obstacles, Problems and/or Known Constraints
• a special washing arrangement needs to be done to prevent lignin reprecipitation.
• leakages and spillages of pulping chemicals cannot be tolerated both for environmental and economical
reasons. However, this is a standard procedure for any petrochemical type operation and the necessary
design features should be incorporated whilst planning.
• difficulty of pulping of mixed species of wood could lead to less homogeneous pulps. This fear has
proven to be unfounded in the various trials taken so far in Canada.
Date Case Study Was Performed: In the early 1985, Pudumjee Mills started work on a laboratory scale.
Over last five years the process went through several tests and trials on a pilot plant scale.
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished material provided by contact person, see 10.4.
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10.2 Citation: Indian Patent No. 167296 dated 6th October, 1990. International Classification - D21C-
3100, 3/02, 11/100.
10.3 Level of Detail of the Source Material: Additional information on the laboratory tests conducted
is available in the source material.
10.4 Industry/Program Contact and Address: K.D. Pudumjee, Technical Director, Pudumjee Pulp &
Paper Mills Limited, Thergaon, Pune 411 033, India.
10.5 Abstractor Name and Address: Dr. R.G. Nayak, Pudumjee Pulp & Paper Mills Ltd, Thergaon,
Pune 411033, India, tel: 86032/33/34, 86488, fax: (0212) 86294, telex: 146-215 GPGL IN
11.0 Keywords
11.1 Waste type: Agricultural residues, Lignin, Hemicelluloses
11.2 Process type/waste source: Pulping process, Delignification, Alcohol, Depithed bagasse
11.3 Cleaner Production Technique: PUNEC pulping process, Solvents, Alcohol
11.4 Other Keywords:
11.5 Country Code: India.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Agricultural residues, Lignin, Hemicelluloses, Pulping process, Delignification, Alcohol, Depithed
bagasse, PUNEC pulping process, Solvents, Alcohol
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Effluent-free and potassium-based sulphite pulping of flax straw with reuse of spent pulping
liquor and bleaching effluent as saleable fertilizer product..
2.0 SIC/ISIC Code: 13411,13512
3.0 Name and Location of Company:
Canadian Flax Pulp Ltd. (Arbokem Inc.), Surrey, British Columbia.
4.0 Cleaner Technology Category
Virtually effluent-free mill as all pulping liquor, bleaching effluent, and fibrous rejects will be collected
for subsequent processing into value-added potassium fertilizer. No burning of spent pulping or bleaching
liquor. Thus, there will be no emission of odorous sulphur compounds and excess carbon dioxide to the
atmosphere.
5.0 Case Study Summary
5.1 Process and Waste Information: The process line includes rotary digesters, pulp washers, bea-
ters/refiners, screens/cleaners, a two-stage bleachery, pulp dryer, evaporator and activated sludge
system for evaporator condensates.
Arbokem proposes to use its new patented process for producing pulp from flax straw and for
disposing of spent pulping liquor. A potassium alkaline sulphite process will be used to produce
the brown flax pulp. The alkaline/neutral sulphite pulp will be bleached to 80-points brightness
using an oxygen-hydrogen peroxide process sequence. The spent pulping liquor as well as the
bleaching effluent is to be collected and evaporated to a saleable liquid fertilizer product. All of
the evaporator condensate and excess white water is to be treated biologically in a small activated
sludge system. Ninety-five percent of the bio-treated effluent is to be recycled for use within the
pulping and bleaching processes. The remaining 5 % of the bio-treated effluent will be discharged
into the municipal sanitary sewer.
In the event of potassium-base supply interruption and to diversify the market for concentrated pulp
mill liquor, Arbokem states that a secondary use of the concentrated spent pulping liquor could be
for road construction. A patented new road construction technology, known as "BC Stabilizer",
requires lignosulphonate. The effluent produced in the flax pulping process can be used as the
lignosulphonate component of the BC Stabilizer.
5.2 Scale of Operation: The pulp mill is designed'to produce 7,000 air-dried metric tonnes of bleached
flax pulp annually, at full capacity, primarily for the export market. The flax pulp mill will also
co-produce 13,000 tonnes (as 50% dissolved solids and 50% water) of potassium-based liquid
fertilizer.
5.3 Stage of Development: A small-scale mill will be fully operational in late 1992.
5.4 Level of Commercialization: The technology is commercially available.
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6.0
7.0
8.0
5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before
Waste Generation:
BOD N/A
COD N/A
TSS N/A
SO2 N/A
CO2 N/A
Feedstock Use:
flax fibre N/A
potassium sulphite 12.7 t/d
potassium hydroxide 1.32 t/d
oxygen 0.55 t/d
hydrogen peroxide 1.32 t/d
epsora salt 0.22 t/d
DTMPA (chelate) 0.22 t/d
Water Use: N/A
Energy Use:
electrical N/A
low press, steam
Economics*
Quantity After
<0.5 kg/d
2.5 kg/d
1.0 kg/d
<2.0 kg/t pulp
18 t/d
12,000 t/y
100 m3/d
760 kWh/admt pulp
13 GJ/admt pulp
6.1 Investment Costs: The proposed bleached flax pulp mill is estimated to cost $8 million Canadian
(April 1991) to construct.
6.2 Operational and Maintenance Costs: The proposed mill would employ 23 full-time workers, with
an estimated annual payroll of $900,000 Canadian.
6.3 Payback Time:
Cleaner Production Benefits
See 4.0.
Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: Arbokem filed its Prospectus document with the Major Project steering
Committee on October 25, 1990.
10.0 Contacts and Citation
10.1 Type of Source Material: Reviews of the project
10.2 Citations:
(1) Review of prospectus for Arbokem Inc. flax pulp mill, Prepared by: The Steering Committee
of the Major Project Review Process, February 1991, Ministry of Regional and Economic
Development & Ministry of Environment, 21 p.
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(2) Bleached flax pulp mill, Prospectus, October 1990, Arbokem Inc., 25 p.
10.3 Level of Detail of the Source Material: Additional information on the environmental and socio-
economic impacts of the project is available.
10.4 Industry/Program Contact and Address: Mrs Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 20s',
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf
10.5 Abstractor Name and Address: Same as in 10.4.
11.0 Keywords
11.1 Waste type: Pulp mill effluent
11.2 Process type/waste source: Sulphite pulping
11.3 Cleaner Production Technique: Potassium based sulphite pulping
11.4 Other Keywords: Flax pulp mill, effluent-free, potassium, fertilizer, road construction
11.5 Country Code: Canada.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp mill effluent, sulphite pulping, potassium-based sulphite pulping, flax pulp mill, effluent-free,
potassium, fertilizer, road construction
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DOCNO: DOCUMENT NOT AVAILABLE
1.0 Headline: Organosolv Pulping of Sugarcane Bagasse
2.0 SIC/ISIC Code: 13411, 13122.
3.0 Name and Location of Company:
ICATn (Institute Centroamericano de Investigacion y Tecnologia Industrial), Guatemala.
4.0 Cleaner Technology Category
This organosolv pulping process uses sugarcane bagasse as raw material and ethanol-water and sodium
hydroxide as cooking liquor, adding anthraquinone (AQ) as catalyst. The process has a closed circulation
of effluents, uses the raw material totally and process residues can be used as raw material in biochemical
processes due to their high content of hexoses and pentoses.
This technology is suitable for modification of old pulping processes. Very important aspects are the total
use of raw material and closed circulation of effluents. The process residues are valuable raw materials
for biochemical processes.
5.0 Case Study Summary
5.1 Process and Waste Information: One of the experiments carried out was as the following:
The cooks were carried out in six, two-liter unit reactors heated in an oil bath and rotating on a
shaft at six rpm. The cooking liquor consisted of a mixture of 60-40% ethanol-water by weight and
small quantities of sodium hydroxide. The amount of AQ was 0.05 %.
The following factors were held constant:
• time to operating temperature, 140 min.
• cooking temperature, 175°C.
• solid to liquid ratio, 1:6.
Once the cooking cycle was concluded, each unit was quickly cooled by immersion in water. The
cooked material was separated from the cooking liquor and thoroughly washed with fresh water;
successively, the material was fiberized in a two-liter blender and screened on a flat screen. The
pulps were then refined at different oSR freenes in a PFI refiner. Sheet making and testing was
done according to TAPPI test methods.
The results of the cooks show that the AQ increases the selectivity of the system toward the lignin
removal and reduces cellulose and hemicellulose degradation effect. The influence of the AQ also
reflected on the physico-mechanical properties of the pulps. In a general way, most properties
improved their values, mainly the tensile and tear index, with the exception of the folding endurance
which showed an important decrease in its values for all the pulps.
5.2 Scale of Operation: The scale of operation is versatile. Already small scale production is
economically feasible and existing pulp mills can be modified for this process.
5.3 Stage of Development: Organosolv pulp process has been theoretically studied since the 1030's.
New development work for the use of tropical wood species, sugar cane and banana leaves as raw
material has been done by the Central American Research Institute for Industry (1CAITI).
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6.0
5.4 Level of Commercialization: The process consists of conversion of existing technology. Large
scale commercialization has not been done.
5.5 Material/Energy Balances and Substitutions: A material balance of the process referred to a 50
t/day plant:
IN (t/dav)
Bagasse (60% H2O) 227.79
H2O 53.29
EtOH (190° proof) 354.91
Anthraquinone 0.05
NaOH (50% H20) 3.64
Economics*
OUT ft/dav't
Pulp 50.00
EtOH (regenerated) 295.22
EtOH (dissipated) 32.80
Lignin 18.22
Sugars (90.6% H2O) 243.44
6.1 Investment Costs: The investment cost for a 50 t/day plant capacity is $CA 21.5 million (1988).
6.2 Operational and Maintenance Costs: The operational costs are $CA 370 per ton of pulp and the
by-product credits $CA 141 per ton of pulp.
6.3 Payback Time: The payback period will be three years (pulp cost $CA 500/t).
Cleaner Production Benefits
Use of new raw material, which can be biomass wastes existing already in large quantities like sugar cane
7.0
Totally integrated use of raw material.
Decrease of waste effluents due to recirculation of effluents and replacement of chemical additives used
in conventional pulp mill.
The pulp mill can be installed locally in small scale close to an area where non conventional raw materials
are available. The socio-economical benefits of a small scale production are superior to those of centralized
production.
8.0 Obstacles, Problems and/or Known Constraints
Due to the volatility of the pulping chemicals no leaks and spills can be tolerated, both for environmental
and economic reasons.
9.0 Date Case Study Was Performed: This case study has been reported by ICAITI during 1984-89.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
10.2 Citations:
(1) Valladares, J., Rolz, C., Bennudez, M.E., Batres, F.R. and custodio, M.A., Pulping os
sugarcane bagasse with a mixture of ethanol-water solution in presence of sodium hydroxide and
anthraquinone, Tappi Nonwood Plant Fiber Pulping Program, Report no 15:23-28, Nov. 1984.
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(2) Dominduez, J.L. and Valladares, J.L., Obtencion de pulpas a partir de tres variedades de
eucaliptus utilizando como Hcor de coccion mezclas de etanol-aqua-sosa en presencia de
antraquinona, pp. 143-146.
(3) Valladares, J. and Cruz, E.G., Obtencion de pulpas quimicas a partir de bagazo de cana de
azucar, utilizando mezclas de metanol-aqua y etanol-aqua, IV Latinoamerican Congress on Cellulose
abd Paper, Proceedings, Mexico 1986, pp. 134-142.
(4) Valladares, J.L., Duarte, F.C., Rolz, C.A. and Perez, E.H.G., Especies arboreas de rapido
crecimiento como fuentes potentiales de celulosa y papel, V Latinoamerican Congress on Cellulose
and Paper, Proceedings, Santiago 1989, pp. 71-88.
(5) Valladares, J.L., Rolz, C. and Perez, E.H., Residuos fibrosos del culfivo del banano como
fuentes potenciales de celulosa y papel, Augura Ano, 14, No. 1, 1988, pp. 65-72.
(6) Valladares, J., Salguero, R., Rolz, C. and Perez, E., Obtencion de pulpas quimicas a partir de
bagazo de cana de azucar utilizando mezclas de etanol, aqua y amoniaco, paper to be presented in
Torremolinos in June 1992, 10 p.
10.3 Level of Detail of the Source Material: Additional information on the pulping conditions is
available in the source material.
10.4 Industry/Program Contact and Address: Valladares, Jaime, Head of the Pulp and Paper Section
of the Applied Research Division Of ICAITI, Avenida La Reforma 4-47, Zona 10-01010,
Guatemala.
10.5 Abstractor Name and Address: Mrs. Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: Chemical pulping, Organosolv lignins, Delignification, Bagasse pulping
11.3 Cleaner Production Technique: Organosolv pulping, Alcohols, Methanol, Anthraquinone
11.4 Other Keywords:
11.5 Country Code: Guatemala.
12.0 Assumptions
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Chemical pulping, Organosolv lignins, Delignification, Bagasse pulping, Organosolv pulping, Alcohols,
Methanol, Anthraquinone
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
4.0
5.0
Headline: Production of higher value paper products from depithed sugarcane bagasse.
SIC/ISIC Code: 13411
Name and Location of Company:
Institute de Pesquisas Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose
e Papel, P.O.Box 7141,01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353 telex-
11 83144 INPTBR.
Cleaner Technology Category
Production of high-yield pulp from depithed sugarcane bagasse.
Case Study Summary
5.1 Process and Waste Information:
Process Area: Pulping.
Base Process: Cold soda semichemical process. The conventional process requires that the
sugarcane bagasse undergoes a depithing process followed by pulping of the fraction rich in fibres
in a cold soda process (10-12% of NaOH over dry matter; 120-140°C during 20-30 minutes). The
pulp produced is normally used to manufacture liners and corrugating medium. This pulp can be
bleached and used to produce, in mixture with secondary fibres, printing and writing papers.
Process Changes: The equipment lay-out is the same, but the chemicals applied are less, and the
pre-steaming time and the temperature of the steam are lower.
New Waste Stream: The same as in regular sugarcane cold soda process, but with lower content
in pollutants.
Raw Materials: Sugarcane bagasse.
Energy Usage: Somewhat higher, between 300-500 kWh/t of drymatter.
Operating Procedures: Normal procedures for the operations already described.
5.2 Scale of Operation: The same as used in the sugarcane semichemical process, between 50-100
ADMT/day.
5.3 Stage of Development: Pilot plant trials.
5.4 Level of Commercialization: The basic conditions are established, but additional research is
necessary.
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5.5 Material/Energy Balances and Substitutions:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
6.0 Economics*
6.1 Investment Costs: Between 150-200 thousands US$/ADMT/day.
6.2 Operational and Maintenance Costs: Depend on the case.
6.3 Payback Time: Depend on the case.
7.0 Cleaner Production Benefits
Substitute a polluting process for another less polluting.
8.0 Obstacles, Problems and/or Known Constraints
None.
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article, personal contacts, conference proceedings, unpublished
material.
10.2 Citations:
(1) Neves, J.M., Pastas quimitermomecanicas de bagaco de cana-de-acucar. O Papel 46(12): 127-
140(1985).
(2) Neves, J.M. e Souza, A., Pastas quimitermome canicas obtidas a partir de bagaco
desmedulados. 8 Encontro de PAR: Materias-primas alternative. Realizado pela Sub Comissao
de PAR de Comissao Permanente de Celulose, ABTCP, Sao Paulo, 1991.
10.3 Level-of Detail of the Source Material: Well detailed.
10.4 Industry/Program Contact and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas
Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel,
P.O.Box 7141,01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex:
11 83144 INPTBR.
10.5 Abstractor Name and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas Technologicas
do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel, P.O.Box 7141,
01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex: 11 83144INPT
BR.
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11.0 Keywords
11.1 Waste type: Liquor
11.2 Process type/waste source: CTM Pulping, Waste liquor
11.3 Cleaner Production Technique: Process substitution
11.4 Other Keywords:
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Liquor, CTM Pulping, Waste liquor, Process substitution
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*****DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Enzymatic post-treatment of IMP obtained from depithed sugarcane bagasse to produce
reducing sugars for ethanol production.
2.0 SIC/ISIC Code: 13511.
3.0 Name and Location of Company:
Institute de Pesquisas Technologicas do Estado de Sao Paulo S. A. - IPT, DPFTC - Agrupamento Celulose
ePapel, P.O.Box 7141,01064-970-Sao Paulo SP-Brasil, phone: 55 11268221 l.fax: 55 11 8693353, telex:
11 83144INPTBR.
4.0 Cleaner Technology Category
An alternative method for the use of sugarcane bagasse that permits production more ethanol in the regular
process, instead of bagasse burning. This kind of process is of great importance in regions where only
ethanol is produced instead of sugar.
5.0 Case Study Summary
5.1 Process and Waste Information: Base Process: The literature shows that in the PEADCO process,
the sugarcane bagasse is depithed by the dry wash and the wet methods. In some mills, one, two
or the three methods are used consecutively producing the depithed bagasse that contains
approximately 19 % of pith and 81 % of fibres. This raw material feeds the cold soda process for
corrugated liner pulp production.
Process Changes: This alternative takes the depithed bagasse, passes it through a pressurized
refiner, as in the first step of a TMP process (thermomechanical), only applying less energy. This
results in some solubilization of hemicelluloses and waxes and makes the cellulose more accessible
to future enzymatic attack. The pulp produced in the TMP process is then squeezed into a screw
and treated with the enzymatic liquor containing Trichoderma reese. During 3-4 hours, the treated
material is saccharified; the sugar liquor is removed through filtration and sent to the ethanol mill
in the fermentation area. The solid residue, containing the micelium, is partly removed and partly
reutilized in the process. The rest can be compressed into pellets for burning in the furnace.
New Waste Stream: When the sugarcane bagasse is depithed, a big volume of the pith is separated.
This is a material rich in starch that can be hydrolized into sugar through acid or enzymatic
methods and then also converted to ethanol.
Raw Materials: Sugarcane bagasse.
Energy Usage: About 200-300 kWh/t of dry bagasse are needed for the TMP operations.
Operating Procedures: Same as described in "Process changes".
5.2 Scale of Operation: In full-scale production, an ethanol mill has a modular output of 1,200,000
litres per day. This output can be increased with enzymatic production.
5.3 Stage of Development: Bench scale.
5.4 Level of Commercialization: This technology is not yet ready for commercialization. A technical
and economic evaluation of the process is being carried out
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5.5 Material/Energy Balances and Substitutions
Material Category Quantity Before
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
6.0 Economics
6.1 Investment Costs: Between US$ 2CKK300 thousand/BDT of pulp processed per day.
6.2 Operational and Maintenance Costs: Variable in each case.
6.3 Payback Time: Not available.
7.0 Cleaner Production Benefits
The increase in production capacity of a regular ethanol mill, by using bagasse to produce ethanol instead
of burning.
8.0 Obstacles, Problems and/or Known Constraints
Price and availability of the sugarcane bagasse.
9.0 Date Case Study was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Personal contact, conference proceedings and un-
published material.
10.2 Citations:
(1) Neves, J.M., Pastas quimitermomecanicas de bagaco de cana, O Papel 46 (12): 127-140, Sao
Paulo, 1985.
(2) Peres, C.S., Schimidell, W., Lima, A.F., Neves, J.M., Villen, R.A. and Sanros, T.W.,
Hidrolise enzimatica de bagaco de cana-de-acucar, i Simposio Interamericano sobre Biotecnologia
de Enzima, OEA/Conselho de Investigaciones Biomedicas Univ. Nacional do Mexico, 10-12 Dez.
1981, In: Mutton, C., ed., Biotecnologia de Enzimas, UNAN, 1983, p. 297-308.
10.3 Level of Detail of the Source Material: Fairly well detailed.
10.4 Industry/Program Contact and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas
Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel,
P.O.Box 7141, 01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex:
11 83144INPTBR.
10.5 Abstractor Name and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas Technologicas
do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel, P.O.Box 7141,
01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211. fax: 55 11 8693353, telex: 11 83144 1NPT
BR.
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11.0 Keywords
11.1 Waste type: Sugarcane bagasse.
11.2 Process type/waste source: Recycling of sugarcane bagasse.
11.3 Cleaner Production Technique: Alternative method to use sugarcane bagasse, Ethanol.
11.4 Other Keywords:
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Recycling of sugarcane bagasse, Alternative method to use sugarcane bagasse, Ethanol.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Recovery of by-products and pulping chemicals from industrial soda bagasse spent liquors.
2.0 SIC/ISIC Code: 13411,13529
3.0 Name and Location of Company:
The Division for Processing and Chemical Manufacturing Technology, CSIR, P.O.Box 395, Pretoria, 0001
South Africa
4.0 Cleaner Technology Category
A serious environmental problem can be solved by the recovery and use of lignin and hemicellulose and
the recycling of chemicals from spent liquors from bagasse pulping.
5.0 Case Study Summary
5.1 Process and Waste Information: Soda bagasse spent liquor contains three useful products - lignin,
hemicellulose, and the spent pulping chemicals. There are various avenues by which these
components can be separated.
In this study, the spent liquor from industrial bagasse soda pulping was subjected to a series of
treatments to separate the valuable components. The concentrated liquor was mixed with an equal
quantity of methanol, resulting in the precipitation of the hemicellulose. Filtration, washing with
50% aqueous methanol, and drying (105°C) gave a hemicellulose precipitate in a 30% yield. The
methanol and part of the water were removed under reduced pressure from the filtrate to give a
lignin solution with a solids content of 33 %. The concentrated solution was acidified with CO2 to
pH 9.5, resulting in precipitation of the lignin. This precipitate was filtered and dried. The lignin
yield obtained by this treatment is influenced by the concentration of the liquor.
The results show that the main portion of the silica is removed from the spent liquor by the
hemicellulose precipitate. This leads to various exciting possibilities of recovery.
The removal of the silica results in an almost silica-free liquor, eliminating the recovery restrictions
previously imposed by the silica in the recovery of soda bagasse pulping chemicals. The liquor
remaining after the removal of the lignin can now be burnt via standard recovery procedures, if
enough energy is present in the form of unrecovered organic material. Another approach is to
remove only the hemicellulose and bum the lignin filtrate for recovering the pulping chemicals.
Soda bagasse hemicellulose has found use as a paper strengthener, a corrugated board adhesive, and
a briquette binder, whereas soda bagasse lignin is an excellent substitute for phenol and urea
formaldehyde adhesive.
5.2 Scale of Operation: In the experimental procedures, the amount of the industrial spent liquor
obtained from the soda pulping of bagasse was 100 g (solids content 30.8 %) and the mixed
methanol amount 100 g.
5.3 Stage of Development: Laboratory stage. Industrial pilot plant evaluations are under way.
5.4 Level of Commercialization: The technology is not commercially available. The equipment and
materials are readily available.
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5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before Quantity After
Waste Generation: N/A N/A
Feedstock Use: N/A N/A
Water Use: N/A - N/A
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time: Reclaiming the lignin and hemicellulose as by-products can increase the profitability
of bagasse pulp mills because the values of these products are estimated to be much more than their
reclamation costs. In addition, the major portion of the sodium can be recovered for the recycling
by a process that is potentially inexpensive in terms of capital investment.
7.0 Cleaner Production Benefits
See 4.0.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: The experimental procedures were presented in 1987.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article.
10.2 Citation: Venter, J.S.M. and Van der Klashorst, G.H., The recovery of by-products and pulping
chemicals from industrial soda bagasse spent liquors, Tappi Journal, March 1989, pp. 127-132
10.3 Level of Detail of the Source Material: Additional information on the uses of by-products is
available.
10.4 Industry/Program Contact and Address: J.S.M. Venter and G.H. Van der Klashorst, program
managers, Division for Processing And Chemical Manufacturing Technology, CSIR, P.O.Box 395,
Pretoria, 0001 South Africa.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulp plant effluent
11.2 Process type/waste source: Soda pulping, Chemical pulping
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11.3 Cleaner Production Technique: Desilication, Recovery
11.4 Other Keywords: Spent liquors, Bagasse, By-products, Adhesive, Binder
11.5 Country Code: South Africa.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
; factors.
Keywords: Pulp plant effluent, Soda pulping, Chemical pulping, Desilication, Recovery , Spent liquors, Bagasse,
By-products, Adhesive, Binder
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*****DOCNO: 400-110-A-325*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Application of the black liquor disilication technology increases efficiency
and eliminates environmental pollution of alkaline non-wood plant fibre
pulping.
Manufacture of Pulp, Paper and Paperboard/ISIC 3411
Removal of silica from spent liquors of alkaline non-wood plant fibre
pulping. When using non-wood annual plant as raw material for pulping,
a considerable amount of silica (SiO^ is carried into the process, which
prohibits recycling of the quick lime to the causticizing process. The
desilication of the black liquor requires steam boiler flue gas as the only
reagent. Precipitated matter is separated from the liquor by means of
conventional mechanical systems (centrifuging, sedimentation, etc.)
Steam boiler flue gas, black liquor containing dissolved silica
Precipitated silica, clarified black liquor recovered in the process.
Solid, liquid
Not reported
Not reported
Not reported
Not reported
Not reported
Low waste technology allows for recycling of quicklime
Current technology generates 250-300 kg CaCO3 solids as lime mud per ton
of dissolved black liquor solids. Low waste technology produces 15-125 kg
SiO2 solids per ton.
Many pulp mills processing straw species with extremely high silica content
are still running without any chemical recovery system due to silica
problems. They are draining their spent liquor into the effluent system and
are forced to cover their demand on pulping chemicals by purchases from
the market. Application of the black liquor desilication technology would
allow them to operate with a chemical recovery system, increasing their
efficiency and eliminating environmental pollution.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Desilication of Spent Liquors Derived from
AldalinePulpingof Non-wood Fibres," Monograph ENV/WP.2/5/Add. 110.
Pulp, Paper, Recycling, Solid Waste Recovery, Silica, ISIC 3411
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Chemicals recovery and disilication of rice straw black liquor.
2.0 SIC/ISIC Code: 13411,13511
3.0 Name and Location of Company:
The Rakta General Co. of Alexandria, Egypt.
4.0 Cleaner Technology Category
The process described allows chemicals to be recovered from rice straw black liquor and an efficient
desilication is attained.
5.0 Case Study Summary
5.1 Process and Waste Information: la general, the quantity of chemicals needed for the digestion of
non-wood materials ranges between 20-50 weight percent of the pulp produced. For the economical
reason, and also to prevent environmental pollution, the chemicals should be recovered from the
spent black liquor.
With chemical pulp produced from rice straw, about half the quantity of silica contained in the plant
substance is dissolved in black liquor (rice straw contains 8-14% SiOj). This causes problems in
all stages of the chemical recovery process.
For a pulp mill that depends on nonwood fiber, silica must be eliminated from black liquor to
produce pulp economically and to meet environmental restrictions.
In the proposed chemicals recovery and desilication process, black liquor coming from the washing
unit is filtered in a drum-filter. The outcoming black liquor is fed via a buffering tank, to the four-
effect evaporation plant For low concentrations, evaporation takes place in three long-tube falling
film evaporators. Higher concentrations are attained in a forced circulation evaporator, which pre-
concentrates the black liquor to a DS content of between 8 and 14% - the optimum for effective
desilication. The forced-circulation stage further concentrates the desilicated black liquor.
Next, a stream of preconceatrated black liquor is fed to a draft-tube reactor equipped with stirrer
and foam breaker, where it is brought into intimate contact with a continuous stream of flue gas
from the power station stack. Here, soluble sodium silicates are converted into sodium carbonate
and largely insoluble SiOj. This two-phase mixture is routed via an intermediate tank to a decanter
that separates the precipitates from the clean liquor. For final clarification, the liquor is passed
through a separator, where the residual insoluble particles are removed. Subsequently, this
desilicated black liquor is then burned in the conventional way.
The silica extracted from the black liquor together with some alkali and organic matter forms a
sludge that is discharged from the decanter at a DS content of 30-40% and burned in a fuel oil-fired
incinerator. Elution of the alkali from the ash with water, followed by filtering and drying, yields
an almost white silica granulate, which can be used as a filler in papermaking.
The optimum pH is between 9 and 10. The corresponding specific flue gas rate at a CO2
concentration of 6-8% is in the range 50-150 m3 gas (at NTP) per m3 of black liquor.
Irrespective of the silica content of the incoming black liquor, which typically is in the range of 1 %
(by weight), total silica contents of 0.05% weight were attained downstream of the separator.
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5.2 Scale of Operation: The research work was carried out in a pilot plant installed at the Rakta Mill,
the largest pulp mill based on rice straw in the world. All process stages were studied in detail,
with researchers carrying out 95 test runs.
In the pilot drum-filter throughput is 30 mVh and the evaporation capacity is 18.5 tons/hour.
Rakta's pilot plant successfully handles 50 tons/day of pre-concentrated black liquor.
5.3 Stage of Development: Pilot plant stage.
5.4 Level of Commercialization: The technology is not commercially available. One of the major aims
of the research project was to find the most suitable equipment available on the market to meet the
various process requirements.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
6.0 Economics*
6.1 Investment Costs: Cost calculations made for some actual projects show that the desilication plant
accounts for only 12% of the total investment cost of a conventional recovery plant.
6.2 Operational and Maintenance Costs: See 6.1. Likewise, labor and utility costs are in the same,
relatively low range. A calculation made for a 200-ton/day pulp mill resulted in total operating costs
for a caustic-soda recovery plant including desilication of $80/ton pulp (1986). Without recovery,
the mill has to spend $140/ton to buy caustic soda on the market. In this case, annual savings by
chemicals recovery amount to $3.6 million, or 13.3 % of the international market value of the pulp.
6.3 Payback Time:
7.0 Cleaner Production Benefits
Among the advantages of the new recovery system are:
Only small losses of alkali and lime by purging out last traces of SiCfe and less waste in the form of Ca
silicates.
8.0 Obstacles, Problems and/or Known Constraints
If improved dewatering properties of silica sludge could be achieved on a commercial scale, even higher
sludge concentrations would be obtained, which in turn would reduce chemical and organic losses
correspondingly.
Disposal of silica sludge is still another area for study. In addition to the silica uses in the papermaking,
bricks can be made with a mixture of 70% sludge (untreated, dry content 10%), 15% gravel, 5% sand.
and 10% cement with a quality that met approved standards.
9.0 Date Case Study Was Performed: The investigation of desilication of rice straw black liquor started in the
1970s. The pilot plant started in 1985.
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10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
10.2 Citations:
(1) Marcks, R. and Schildhauer, G., Trials prove black liquor system, PPI, November 1986, pp
48-49.
(2) Kopfmann, K. and Hudeczek, W., Desilication of black liquor: pilot plant tests, Tappi journal,
October 1988, pp. 139-147.
10.3 Level of Detail of the Source Material: Additional information on the individual process stages is
available in the source material.
10.4 Industry/Program Contact and Address: L. Ehling, Kraftanlagen Aktiengesellschaft, Wamgauer
Str. 47, P.O.Box 900465, 8000 Munchen 90, Germany, Tel. (0049) 89-6237326, Fax. (0049) 89-
6237335.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulp mill effluent
11.2 Process type/waste source: Recovery
11.3 Cleaner Production Technique: Desilication
11.4 Other Keywords: Rice straw, Black liquor
11.5 Country Code: Germany, Egypt.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp mill effluent, Recovery, Desilication, Rice straw, Black liquor
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Chemicals recovery of wheat/rice straw pulping waste liquor
Experiences on chemical recovery of 50 t/d bleached wheat/rice straw pulping waste liquor.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Shanghai Xin Hua Paper Mill, 3520 Yi Xian Road, Bao Shan District, Shanghai 200940, P.R.China, tel:
6673455.
4.0 Cleaner Technology Category
Based upon many years efforts, some characteristics of straw pulping black liquor can be modified to a
certain extent, so as to conform to the requirement of alkaline recovery. Meanwhile, the design and
operation of the equipment must accommodate the straw black liquor as possible. As a result of many
efforts, the alkali recovery system of straw pulping black liquor can run regularly nowadays.
5.0 Case Study Summary
5.1 Process and Waste Information: Long-term practice reveals that applying conventional wood
pulping alkaline recovery system to treat that of straw pulp is unsuitable. Wheat (as well as rice)
straw pulping black liquor is characterized by high silica content and high viscosity, which cause
evaporating problems, as well as low heat value which calls for much more supplementary heat
energy. Moreover, as a result of high silica content of the liquor, impermeability on the ignite char
bed of furnace bottom arises more easily, and the ash build-up phenomenon on the heated surface
is severe.
According to the statistics in 1990, the annual commercial caustic soda consumption of Chinese pulp
and paper industry reached 1,200,000 tons and only 350,000 tons were recovered. Lots of
commercial NaOH were consumed by numerous small and straw pulp mills. The key problems
hampered the regularly alkali recovery of straw black liquor are:
• High silica content of the black liquor, which causes scale problems not only in the evaporators,
but also in the washing wires.
• High viscosity of the black liquor, especially the concentrated liquor (TS > 40 %), which hampers
the further concentration of the liquor to desired concentration (>50%).
• High silica content of the liquor results difficulties in the recovery furnace (lower volumetric
isothermal expansivity V.I.E.) as well as the recovery of lime.
In Chinese paper industry, long-term alkali recovery rate of straw pulp waste liquor in most mills
is about 50-55 %. Few of them reached 60 % or more. The report of Xin Hua Paper Mill represents
the experiences of efforts made by the industry.
Original manufacturing process:
• wheat straw: NaOH 17%; Peatosan of the B.L. 10.15%; SiO^ in TS 1.86%; Viscosity Pa.S of
B.L. 0.72
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6.0
• rice straw: NaOH 11%; Pentosan of the B.L. 10.55%; SiOj in TS 3,57%; Viscosity Pa.S of
B.L. 2.07
Black liquor extraction: no consistency adjusting device; lower extraction rate and concentration of
the liquor.
Evaporation: long-tube rising film evaporators, serious scaling problem.
Furnace: flying ash and ash building up problems.
5.2 Scale of Operation: 50 t/d straw (wheat straw takes main part) alkaline pulping waste liquor
recovery system.
5.3 Stage of Development: Full productional scale application, and certain improvements are
undertaken.
5.4 Level of Commercialization: The technology can be commercialized.
5.5 Material/Energy Balances and Substitutions: Cooking conditions
Wheat straw
Rice straw
NaOH
13%
7%
NajS03
3%
3%
Pentosan of
the B.L.
7.44%
8.55%
SiO2 in TS
1.19%
1.83%
Viscosity Pa.s
of B.L.
0.36%
0.39%
Black liquor extraction: consistency adjusting device added.
Evaporation: Short-tube evaporators with circulation, suitable operation schedule established.
Furnace: many improvements were achieved to obtain better operation, such as the diameter and
height of spray nozzle, the enough height of furnace, etc.
Caustization: chute-type clarifier, horizontal belt vacuum filter, etc.
Lime mud producer: is planned to be converted to CaCO3 for paper filler and coating materials
with the successful experience of Yuan Jiang Paper Mill,Hunan Province.
Black liquor extraction rate: >85% (TS 10.5%).
Evaporating effect (concentration of B.L. 43-45%): evaporation intensity 10-12kg/m2h, evaporation
efficiency 3 kg water/kg steam.
Furnace/Boiler (model WGZ-13/9-1, made by Wu Han Boiler Factory, Hubei Province): heat
efficiency reaches 70%.
Long-term alkali recovery rate: about 60%, and is further improved to 75% recently.
Economics*
6.1 Investment Costs: Not available.
6.2 Operational and Maintenance Costs: Not available, but in comparison with the price of commercial
caustic soda, the recovered alkali may be save the production costs by about 15-20%.
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6.3 Payback Time: Not available, but according to other feasibility studies for new alkali recovery
systems in China, the payback time would be 7-9 years for 30-50 t/d straw waste liquor recovery
systems.
7.0 Cleaner Production Benefits
For a 50 t/d straw pulping mill, the annual recovery of alkali reaches about 400O tons which is a attractive
economic and social benefit. On the other hand, according to the environmental legislation of China, if the
serious pollution caused by the black liquor could not be reduced, the mill should be closed at the end of
1995.
8.0 Obstacles, Problems and/or Known Constraints
Though the alkali recovery rate reaches about 60%, nevertheless, this mill has not finished its rebuild
project yet. The spent liquor occurred from a 15 t/d straw pulp workshop at an old area has not been
reclaimed, which causes underload running of the recovery system, and thus influences the recovery rate.
Moreover, the process technique, equipments and operation skills should be further improved. Through
a series of efforts, the alkali recovery rate may reach 75%.
9.0 Date Case Study Was Performed: May 2, 1992.
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings and unpublished material.
10.2 Citation: Zou, Pei Cheng, The Alkali Recovery System for Black Liquor based on 50 t/d Bleached
Straw Pulp, Proceedings of 2nd International Non-wood Fibre Pulping and Papermaking
Conference, April 6-9, 1992, Shanghai, China, Vol.11, pp. 895-913.
10.3 Level of Detail of the Source Material:
10.4 Industry/Program Contact and Address: Prof. Ke Zhang, China Technical Association of the Paper
Industry, No. 11 Fucheng Road (Beijing Institute of Light Industry), 100037 Beijing, P.R.China,
tel: 890571-476.
10.5 Abstractor Name and Address: Prof. Ke Zhang, China Technical Association of the Paper
Industry, No. 11 Fucheng Road (Beijing Institute of Light Industry), 100037 Beijing, P.R.China,
tel: 890571-476.
11.0 Keywords
11.1 Waste type: Pulping waste liquor, Cooking waste liquor
11.2 Process type/waste source: Alkaline wheat/rice straw pulping
11.3 Cleaner Production Technique: Chemical recovery, Alkali recovery
11.4 Other Keywords:
11.5 Country Code: China.
12.0 Assumptions
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13.0 Peer Review
No.
'(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulping waste liquor, Cooking waste liquor, Alkaline wheat/rice straw pulping, Chemical recovery,
Alkali recovery
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Pilot plant trial of desilication for alkaline wheat straw pulping black liquor by flue gas
treatment to improve the evaporating and lime recovering efficiencies.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Paper Industry Research Institute, Ministry of Light Industry, No. 12 Guangb.ua Road, Beijing 10020,
P.R.China. Tel: 5022561; Cable: 0061.
4.0 Cleaner Technology Category
Silica disturbance is well known as a troublesome question in the recovery of alkaline straw pulping black
liquor, because large quantity of SiO2 contained in the black liquor precipitated and plugged the separating
wire and scaled in the evaporators. This obviously decreased the separating and evaporating efficiencies
of the recovery process. The principles of this case study are: (1) to develop desilication process by CO2
of flue gas and to obtain related parameters; (2) to develop specially designed separator for silica sludge
separation.
5.0 Case Study Summary
5.1 Process and Waste Information: In normal alkali recovery process, the black liquor contained in
the digester pulp is: (1) extracted by vacuum filters etc.; (2) the extracted black liquor is evaporated
and concentrated by multi-evaporators; (3) the concentrated black liquor is burned in the recovery
boiler and (4) the melted sludge mainly NajCOa is caustisized by CaO to form NaOH for reuse and
lime mud can be recovered. Due to silica disturbance as showed in 4.0, a desilication process for
treating alkali wheat straw pulping black liquor by flue gas was investigated through pilot plant
trials. The main operating procedures are: (1) to mix the black liquor with flue gas from the boiler
in an especially designed venturi absorber ((1 - 3): 1000 v/v); (2) to control the pH of black liquor
dropped from 11.1 - 11.85 to 10.3; (3) after reaction, the liquor is settled in a clarification tank;
(4) the silica sludge is separated by a uniquely designed separator to a concentration of 40% and
the total black liquor loss is below 1%. And then, the desilicated black liquor is pumped to the
evaporation station as normal.
The main parameters obtained by this study could be summarized as followed:
Test capacity
SiO2 in original liquor
SiO2 in clarified liquor
Dilute sludge volume
Desilication efficiency
Black liquor loss
Bone dry sludge
Power consumption
3 m3 extracted black liquor/h
6 -8 g/1 .
1.0 - 2.3 gfl
20*
83 - 88%
< 1%
3.5 - 4.1 kg/m3 liquor
< 10 kWh/m3 liquor
In discussion of the study, the authors pointed out:" The pH value of desilicated liquor is reduced,
and also the evaporation efficiency, the ultimate concentration of the liquor. So white liquor or
alkali must be added to increase the pH value of liquor as to satisfy the requirement of
evaporation." Adding white liquor or alkali to satisfy the requirement of evaporation would be a
drawback of this process which calls for further investigation.
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6.0
7.0
5.2 Scale of Operation: Pilot plant trial on a capacity of 1-3 m3 extracted black liquor/h, which roughly
corresponding to 3 tons pulp/day.
5.3 Stage of Development: Pilot plant stage, the quantitative figures showed in 5.1 are estimated based
on pilot test.
5.4 Level of Commercialization: It is far from commercialization as it was only a small scale pilot
trial.
5.5 Material/Energy Balances and Substitutions: Please see 5.1, it is only a reference balance obtained
in pilot trial.
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
Economics*
6.1 Investment Costs: It is difficult to estimate the actual economics from this pilot study. The key
point is whether the evaporating efficiency would be improved, which could not be answered by
the study.
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
Cleaner Production Benefits
Theoretically, the desilication of straw pulp waste liquor can decrease the scaling problem and thus
obviously improves the evaporation efficiency, and at the same time the silica problem caused in lime
recovery may decreased. But it must be proved in productional scale.
8.0 Obstacles, Problems and/or Known Constraints
Many efforts have been made by numerous researchers by different ways, such as flue gas, biological or
precipitating method (adding Ca, Mg, Al precipitants). None of these have been successful in commercial
scale. As for the CO, flue gas method, the investment and maintenance cost would be high due to a large
gas-liquor reactor, fan and separator. Furthermore, 'the flue gas absorbed by the liquor will be liberated
in the evaporators and thus foam problem would occur which will influence the evaporating efficiency in
a negative way.
9.0 Date Case Study Was Performed: Paper presented at the Workshop on Environmental Aspects of Non-
Wood Fibre Pulp and Paper Manufacture, in Hangzhou, China, Nov. 24-28, 1986.
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings.
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10.2 Citation: Fu-ting Ma, Fa-bin Jiao, Pilot plant test run of desilication for alkaline wheat straw
pulping black liquor, Proceedings of the Workshop on Environmental Aspects of Non-Wood Fibre
Pulp and Paper Manufacture, Vol. II, UNEP Regional Office for Asia and the Pacific, September
1987, pp. 478-487
10.3 Level of Detail of the Source Material: A further productional scale test was published by the same
first author of the pilot test in the title: "Production Scale Desilication Experiment from Alkaline
Straw Pulp Black Liquor." The test scale was 250-500 m3 black liquor/day. The silica content in
desilicated clean black liquor was about 0.37 g/1, silica removal rate about 90% and electric energy
consumption was about 5 kWh/m3 black liquor, loss of black liquor < 4%. This report was
published in "China Pulp and Paper" vol. 5, 1991, with English abstract. According to the
discussion of this report, some shortcoming still existed as the foam problem of treated black liquor
occurred in evaporation must be further overcome and the practical benefits of desilication for
evaporation, combustion, as well as the character of lime mud etc. have to be proved in further
practice yet.
10.4 Industry/Program Contact and Address: Fu-ting Ma and Fa-bin Jiao, Paper Industry Research
Institute, Ministry of Light Industry, P.R.China, No. 12 Guanghua Road, Beijing 10020,
P.R.China. Tel: 5022561; Cable: 0061.
10 5 Abstractor Name and Address: Professor Ke Zhang, China Technical Association of Paper
Industry, CTAPI, 11 Fucheng Road, 100037 BEIJING, P.R.CHINA, tel. (01)890571-476.
11.0 Keywords
11.1 Waste type: Black liquor, Waste liquor, Spent liquor, Silica content
11.2 Process type/waste source: Alkaline straw pulping, Wheat straw pulping, Desilication, Silica
removal'
11.3 Cleaner Production Technique: Silica removal, Desilicate, Desilication, Flue gas (COJ treatment
I1-.4 Other Keywords:
11.5 Country Code: China.
12.0 Assumptions
Type and operating parameter of the evaporator used in the pilot test were not given, so it is difficult to
evaluate the variation of the test data about evaporation.
Two consequences would be caused by the CO2 flue gas in contact and reaction with black liquor: (1)
viscosity of straw pulp black liquor would change which do influence the evaporation efficiency, and (2)
' flue gas dissolved in black liquor would cause foam problem during evaporation. Both of these factors must
be further studied for successful application.
The addition of white liquor or alkali to the desilicated black liquor could improve the evaporation
efficiency by decreasing the viscosity of the liquor, but the recovery rate of alkali will decrease due to
incomplete extraction rate of alkali in the causticization process.
13.0 Peer Review
No.
2-306
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Black liquor, Waste liquor, Spent liquor, Silica content, Alkaline straw pulping, Wheat straw pulping,
Desilication, Silica removal, Silica removal, Desilicate, Desilication, Flue gas (COj) treatment
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Development of a technology for desilication of bamboo black liquor.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
The Hindustan Newsprint Ltd (HNL) mill in Nagar, Kerala, India.
4.0 Cleaner Technology Category
The bamboo black liquor desilication technology reduces the BOD and COD discharge loads of a chemical
pulp mill. The desilication technology will benefit many developing countries and will contribute to shift
emerging industrial growth in those countries from an ecologically degrading to an ecologically sustainable
pattern.
5.0 Case Study Summary
5.1 Process and Waste Information: Non-wood fibrous raw materials normally have a higher ash and
silica content than wood. Most of the silica gets dissolved during cooking and remains as an un-
desirable constituent of the black liquor. The silica causes many problems as washing is difficult
owing to the poor drainability of the pulp and high viscosity of black liquor. The outcome is scale-
formation in evaporator tubes; deposits on the furnace walls of recovery boilers, slow setting rate
of caustizing white liquor and lime sludge unsuitable for rebuming.
The presence of silica is a major technical obstacle to the efficient chemical recovery of non-wood
black liquor. Together with the economic barriers, this is one of the reasons why most small- and
medium-sized non-wood pulp mills in developing countries do not have any chemical recovery
systems and thus severely pollute rivers and other water-courses.
Some mills using non-wood raw materials have chemical recovery systems in order to reduce
pollutant loads and recovery pulping chemicals. However, as the lime sludge is unsuitable for
rebuming it is not recovered and large amount of solid waste is discharged in the soil. A mill
producing 120 tpd of bleached pulp and paper from bamboo, generates roughly 16,000 t/year of
lime that need to be dumped outside the mill.
Bearing in mind the problems faced by non-wood based pulp mills, a project was designed to
develop, demonstrate and disseminate a technology for desilication of bamboo black liquor. The
conclusions drawn from the study of available publications on the subject led the project
management to select, as the most promising approach, the pH reduction of dilute or semi-
concentrated black liquor (10-24% TS) using hot recovery furnace gas. The demonstration plant
results were satisfactory and the process is technically feasible.
5.2 Scale of Operation: A full-size demonstration desilication plant was erected.
5.3 Stage of Development: The bamboo black liquor desilication process has been fully implemented.
5.4 Level of Commercialization: Unknown.
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5.5 Material/Energy Balances and Substitutions:
6.0
7.0
9.0
10.0
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
N/A
Quantity After
60-70% reduction
of both the solid
and liquid waste
N/A
N/A
N/A
N/A
N/A
N/A
Economics*
6.1 Investment Costs: The Hindustan Newsprint Ltd (HNL) mill is in the process to install a lime kiln
and only after the installation it will be possible to have cost figures to prepare an accurate
economical evaluation of the process.
6.2 Operational and Maintenance Costs: See 6.1.
6.3 Payback Time:
Cleaner Production Benefits
The desilication technology will enable many mills with chemical recovery to install lime sludge reburaing,
with a reduction of 60-70% of their solid waste disposal. It also will reduce the operational difficulties in
the recovery cycle and will enable a number of mills without chemical recovery to install it, including lime
reburning, with a reduction of 60-70% of the liquid waste disposal.
8.0 Obstacles, Problems and/or Known Constraints
The project faced the normal problems to be overcome in any development of a technology. There are still
some problems to be solved in the demonstration plant such as correct type of filter cloth and instrument
sensors. These however are non-technical problems that are being handled by HNL and CPPR1 and is
expected to be solved.
Date Case Study Was Performed: The UNIDO/SIDA (Swedish Industrial Development Authority)
assignment was to develop a desilication technology for black liquors suitable for use in tropical developing
countries. The work has been funded by SIDA, the government of India and the cooperating pulp mills.
In 1984 the pilot desilication plant was ready to be scaled up to a full-size industrial demonstration plant
and this was erected in the recovery department of an Indian kraft bamboo pulp mill by end 1985.
This effort is still going on for operational fine tune improvements and identification of operational costs
after optimization.
Contacts and Citation
10.1 . Type of Source Material: Unpublished material.
10.2 Citation: An abstract provided by UNIDO.
10.3 Level of Detail of the Source Material: General information on discharge loads is available.
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10.4 Industry/Program Contact and Address: Ralph Luken, Environment Coordination Unit, UNIDO,
Vienna International Centre, P.O.Box 300, A-1400 Vienna, Austria, Telephone: 211 310, telex:
135612 uno a, fax: 232 156.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulp mill solid waste, pulp mill liquid waste
11.2 Process type/waste source: Recovery, Black liquor recovery
11.3 Cleaner Production Technique: Desilication of black liquor
11.4 Other Keywords: Bamboo, Bamboo black liquor, Non-wood black liquor
11.5 Country Code: India.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp mill solid waste, pulp mill liquid waste, Recovery, Black liquor recovery, Desilication of black
liquor, Bamboo, Bamboo black liquor, Non-wood black liquor
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
Headline: The Lignin Removal Process (LRP) provides an approach to effluent treatment for pulp and
paper mill effluents with possible reuse of organic matter recovered from waste liquors.
SIC/ISIC Code: 13411,13412
Name and Location of Company:
Central Pulp and Paper Research Institute, Saharanpur, India (non-wood materials, laboratory scale),
Veitsiluoto Oy, Oulu mill and Suomen Kuitulevy Oy, Pihlava mill, both in Finland (pilot scale).
4.0 Cleaner Technology Category
LRP fits well as a complement to mechanical and biological effluent treatment in that it efficiently removes
biologically slowly decomposing organic material of high molecular mass, as well as, effluent colour.
5.0 Case Study Summary
5.1 Process and Waste Information: The LRP can be used for treating bleach plant, wet barking, fibre
board, TMP and CTMP plant effluent. The pulp mills especially making non-wood pulps are dis-
cussed here.
LRP is a method for removing organic matter from pulp and paper mill effluents and other waste
waters with high organic contents. The process is based on the ability of acidified fibre sludge to
precipitate organic matter from effluents. The zeta potential of the sludge/water suspension used
is reduced almost to zero prior to precipitation with acidic effluent or mineral acid. The presence
in the fibre sludge of acid soluble salts like aluminum, iron and calcium makes precipitation more
effective. The results achieved with the LRP for treatment are similar to those obtained with
aluminum sulphate.
Acidified sludge is mixed with the effluent during mixing, causing precipitation of dissolved organic
material from the effluent. The insoluble material formed binds with the sludge to give solid that
can be removed by sedimentation. The solids are separated from water in a clarifier or, when the
sludge content is high, in a centrifuge. Some of the sludge obtained is recycled and the remainder
dried or used for making products like board.
To protect the separation equipment against corrosion and improve subsequent dewatering, the
water/sludge suspension is neutralized with lime and a suitable polymer, usually cationic, is added.
Sludge recycling is not normally required when the process is used to treat paper and board mill
effluents. The fibre sludge used in these cases is disintegrated waste pulp, which is recycled to
paper or board machine after being used for precipitation of organic material from circulating
water.
The method has given the best results when effluents from non-wood pulp mills have been treated.
The reuse of the recovered organic matter is then possible.
5.2 Scale of Operation: The scale of the laboratory equipment was about 5 1 and the pilot equipment
treated 1-6 m3/hour (2 m3) of effluent
5.3 Stage of Development: Pilot stage.
5.4 Level of Commercialization: The technology is ready for commercialization.
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5.5 Material/Energy Balances and Substitutions: Non-wood pulp and paper mill. Raw materials are
wheat straw and waste paper 50/50.
Material Category
Quantity Before Quantity After
Waste Generation:
COD 400 kg/t product
colour reduction
Feedstock Use: N/A
Water Use: N/A
Energy Use: N/A
140 kg/t product
85%
N/A
N/A
N/A
The effluent volume should be as low as possible (organic matter content 2-10 g/1). Normally no
new raw materials are needed, if some acidic effluent is available. If not, acid and lime will be
needed. The energy balance is calculated case by case. Generally there is no change in energy
consumption.
6.0 Economics*
6.1 Investment Costs: Investment cost for a non-wood based pulp mill in India was 2.5 million FIM
(date February 1992), (effluent flow 1,600 nrVday). There are also other examples but the
investment cost must be calculated case by case due to the high impact of local conditions.
6.2 Operational and Maintenance Costs: Total operating cost (without the benefit from the recovered
fibers and organic matter) was for the above mentioned plant 200 FIM/ton pulp.
6.3 Payback Time: Payback time mainly depends on the value of the recovered fibers and organic
matter. For a possible price, 600 FIM/ton, the payback time is three years.
7.0 Cleaner Production Benefits
The biggest environmental problem for a non-wood pulp mill is the lack of recovery of cooking waste
liquor. The main problem is techno-economical. The raw material contains large amounts of silica, and
evaporation of the waste liquor is impossible in most cases. LRP-method offers an economic measure to
recover the organic matter from the waste liquors.
The COD and colour removal has also been important for developing this method. The biological
purification methods can remove smaller molecules (molecular weight less than 700-800 dalton), but larger
molecules will not be removed. For removal of those compounds, the LRP-method gives new possibilities.
8.0 Obstacles, Problems and/or Known Constraints
There are no technical constraints to foresee. The economy is the most important question, and it mainly
depends on the reuse of the recovered fibers.
9.0 Date Case Study Was Performed: The tests were run in the first quarter of 1992.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
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10.2 Citations:
(1) Hynninen, P., Pilot plant trials for LRP, a new process for precipitating organic material Tappi
Journal, February 1989, pp. 167-170.
(2) Hynninen, P., A mathematical model of the lignin removal process (LRP), Paperi ja Puu -
Paper and Timber, No 10, 1989, pp. 1114-1118.
10.3 Level of Detail of the Source Material:
10.4 Industry/Program Contact and Address: Pertti Hynninen, Enviro Data Oy, P.O.Box 328, 02151
Espoo, Finland, tel. +358-0-43542093, fax. +358-0-465 250.
10.5 Abstractor Name and Address: Pertti Hynninen, Enviro Data Oy, P.O.Box 328, 02151 Espoo
Finland, tel. +358-0-43542093, fax. +358-0-465 250.
11.0 Keywords
11.1 Waste type: Pulp and paper mill effluents, Non-wood pulping effluents, Organic matter, COD,
Colour
11.2 Process type/waste source: Non-wood pulping, Paper and board mills, Fiberboard mills
11.3 Cleaner Production Technique: Waste liquor recovery, Lignin removal process
11.4 Other Keywords: Effluent treatment, Sludge handling, Fiber recovery
11.5 Country Code: Finland, India.
12.0 Assumptions.
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulp and paper mill effluents, Non-wood pulping effluents, Organic matter, COD, Colour, Non-wood
pulping, Paper and board mills, Fiberboard mills, Waste liquor recovery, Lignin removal process, Effluent
treatment, Sludge handling, Fiber recovery
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Synthetic Fibers Pulp Mills
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Eucalypt or other wood pulping with the oil tar fraction from wood dry pyrolysis uses less
energy and affords recovery and reuse of tar oil and lignin residue.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
Institute de Pesquisas Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose
ePapel, P.O.Box7141,01064-970-SaoPauloSP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex:
11 83144INPT BR.
4.0 Cleaner Technology Category
Eucalypt wood pulping with oil tar.
5.0 Case Study Summary
5.1 Process and Waste Information:
Process Area: Waste recycling.
Base Process: The standard process of production of soluble cellulose, used in the rayon and viscose
manufacture, is the kraft process with prehydrolysis. This case represents an alternative to the
standard process, in the same line as the organosolv process.
Process Changes:- Pulping occurs through dissolution of lignin in the wood tar, which is used as
cooking liquor.
New Waste Stream: The oil and lignin become a new waste stream, but the lignin can be recovered
by distillation of the tar oil, and returns to the main process. The solid lignin residue can be used
as raw-material for the production of plastics.
Raw Materials: The tar oil can be obtained by dry pyrolysis of the fine chips, separated in the wood
screening area.'
Energy Usage: In the pulping operation, less energy is used when compared to the conventional
process. Some energy is necessary to recover the cooking liquor.
Operating Procedures: Same as described in Base Process and Process Changes.
5.2 Scale of Operation: Applied in standard kraft process operations, but in full-scale mills with an
output in the order of 100-150 ADMT/d.
5.3 Stage of Development: Partly bench scale and partly pilot scale.
5.4 Level of Commercialization: The basic technology is ready for use; some adjustment is necessary
before commercialization.
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5.5 Material/Energy Balances and Substitutions
Material Category Quantity Before
6.0 Economics
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
N/A
N/A
N/A
N/A
Quantity After
N/A
N/A
N/A
N/A
6.1 Investment Costs: Detailed economic figures have not yet been prepared, but the equipment
suggested in this alternative is of regular use in the areas of pulping and crude oil distillation.
6.2 Operational and Maintenance Costs: Not available.
6.3 Payback Time: Not available.
7.0 Cleaner Production Benefits
Reduction of waste generation in the pulping area when compared with the conventional process.
8.0 Obstacles, Problems and/or Known Constraints
None.
9.0 Date Case Study was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Personal contact and doctoral thesis.
10.2 Citation: Jordao, M.C.S., Uso de alcatrao vegetal como agente deslignificante de madeira de
eucalipto, Tese de Doutoramento, EPUSP-Depto Eng. Quimica.
10.3 Level of Detail of the Source Material: Fairly well detailed.
10.4 Industry/Program Contact and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas
Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel
P.O.Box 7141, 01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353 telex-
11 83144INPTBR. *
10.5 Abstractor Name and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas Technologicas
do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel, P.O.Box 7141
01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex: 11 83144INPT
BR.
11.0 Keywords
11.1 Waste type: Wood tar, Lignin.
11.2 Process type/waste source: Pulping liquor.
11.3 Cleaner Production Technique: Alternative kraft process.
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11.4 Other Keywords:
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wood tar, Lignin, Pulping liquor, Alternative kraft process.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Chemicals and energy consumption reduced and upgraded effluent treatment plant based on
extended aeration activated sludge process added in a pulp plant.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Harihar Polyfibers, Kumarapamani, Dharwar, India.
4.0 Cleaner Technology Category
A significant reduction to the tune of 60% in consumption of chemicals and energy was achieved through
several innovative modifications in the Rayon Grade Pulp Plant This resulted in 50-55% reduction in
influent load to the Effluent Treatment Plant in terms of BOD and suspended solids. For treating the waste
water generated in the process, the Effluent Treatment Plant was upgraded by installing a biological reactor
employing extended aeration activated sludge process.
5.0 Case Study Summary
5.1 Process and Waste Information: The effluents from the plant are segregated into the following four
main streams: prehydrolysaite liquor, pulp mill effluent, bleach plant effluent, and recovery effluent.
Presently, the total installation consists of two primary clarifiers, three anaerobic lagoons, a biolo-
gical reactor and two secondary clarifiers with sludge recirculation systems. In addition to this,
there is a separate treatment system for the prehydrolysate liquor. This system consists of lime milk
addition device, two settling tanks, one cooling pond, two anaerobic lagoons, two aerated lagoons
and a settling pond.
The prehydrolysate liquor is obtained from the prefaydrolysis of the wood chips. The stream is
having the BOD in concentrated form and hence, it is given a separate preliminary treatment before
mixing it with the rest of the effluent for the secondary treatment in the biological reactor.
The combined effluent (i.e., the treated prehydrolysate liquor, primary clarifiers' overflow,
bleaching effluent, and the settled recovery effluent) is jointly led into the three anaerobic lagoons
operating in parallel. Urea and diammonium phosphate are added as nutrients required for the
anaerobic bacteria. The overflow of these lagoons is directed to the biological reactor.
In the aeration tank, the waste liquor is aerated with 17 surface aerators of 40 hp each. Urea and
diammonium phosphate are added. The biomass generated is flocculent and quick settling. It is
separated from the aerated effluent in two secondary clarifiers and the settled bottom sludge is
recycled continuously to the aeration tank as an essential feature of the process. The clear overflow
from the secondary clarifier with a BOD of below 30 mg/1 is discharged to the river. Continuous
bio-monitoring is being done and fish survive comfortably.
5.2 Scale of Operation: Harihar Polyfibers produces 66,000 t/a rayon grade pulp from plantation crops
of eucalyptus, casurina, etc. The effluent treatment plant has been built over an area of 90 acres.
5.3 Stage of Development: Fully implemented.
5.4
Level of Commercialization: The plant was designed and installed by integrating equipments and
know-how available from different sources to meet our specific requirement of quality of final
treated effluent parameters suitable for river discharge.
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5.5
6.0
7.0
8.0
9.0
Material/Energy Balances and Substitutions: Quality of treated effluent before and after installation
of biological reactor employing extended aeration activated sludge process.
Material Category
Waste Generation:
BOD, mg/1
COD, mg/1
TSS, mg/1
Feedstock Use:
Water Use:
Energy Use:
Quantity Before
300
500
350
N/A
N/A
N/A
Quantity After
20
250
80
N/A
N/A
N/A
Economics*
6.1 Investment Costs: Investment costs Rs. 150 lacs (as in the year 1983).
6.2 Operational and Maintenance Costs:
a) Chemical
b) Manpower
• c) Power
d) Maintenance
Rs./day
8,210
1,000
17,188
4,200
Rs.in lacs/annum
29.6
3.6
61.9
15.1
30,598
110.2
6.3 Payback Time:
Cleaner Production Benefits
With the upgradation of the effluent treatment plant by installing Biological Reactor employing Extended
Aeration Activated Sludge Process, the Quality of effluent discharged from the mill improved drastically.
Reduction in BOD was 93% and in Suspended Solids 68%. COD value also came down below the
stipulated limit of 250 mg/1. The downstream river water quality improved considerably and the who-
lesomeness of the water quality was maintained. Ple'nty of fish are available both in the treated effluent
channel leading to the river and also in the downstream river. Fish catch is flourishing.
Obstacles, Problems and/or Known Constraints
No technical constraints.
Date Case Study Was Performed: The installation of Biological Reactor employing extended aeration
activated sludge process was completed in December 1983.
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished material provided by the contact person.
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10.2 Citation: Rajan, T.V.S. and Betkerur, S.N., Environmental management in Harihar Polyfibers,
17 p.
10.3 Level of Detail of the Source Material: Additional information on the waste streams treated and
on the development of the reduction in chemical and energy consumption is available.
10.4 Industry/Program Contact and Address: Mr. S.S. Maru, Grasim Industries Ltd., Kumarapatnam
581 123, Kamataka, India, phone: 08197-2171, fax: 08197-2875, telex: 0834-221 & 224
Shailendra K. Jain, Senior Executive President, Harihar Polyfibers, Grasim Industries Ltd.,
Kumarapatnam 581 123, Dharwar, India, phone: 2271-2175, fax: 08197-2875
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland-, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
11.0 Keywords
11.1 Waste type: Pulping effluent, Prehydrolysate liquor, Bleaching effluent, Recovery effluent
11.2 Process type/waste source: Chemical pulping
11.3 Cleaner Production Technique: Activated sludge, Anaerobic lagoons, Biological reactor
11.4 Other Keywords:
11.5 Country Code: India.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Pulping effluent, Prehydrolysate liquor, Bleaching effluent, Recovery effluent. Chemical pulping,
Activated sludge, Anaerobic lagoons, Biological reactor
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Heat recovery in dissolving-grade pulp plant captures heat from digesters for reuse in bleach
plant.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Harihar Polyfibers, GRASIM, Karnataka, India.
4.0 Clean Technology Category
Technology Principle: This technology involves a heat recovery system which incorporated cyclone
separators for eliminating liquor carry-over in vent vapors.
5.0 Case Study Summary
5.1 Process and Waste Information: This plant is a dissolving-grade pulp plant where the pulp is
produced by employing a pre-hydrolysis sulphate process using mixed tropical hard wood by a
two-stage cooking process. The first stage is called pre-hydrolysis, where in the pentosal, contents
of wood are dissolved in water at high temperatures and acidic conditions. After the cooking is
completed, the digester is vented and the liquor content is drained out. A considerable amount of
heat was being wasted to the atmosphere by way of vent vapors and hot poly-hydrolysate (PH)
liquor.
To avoid this heat wastage, a properly designed heat recovery system was introduced, incorporating
suitable cyclone separators for eliminating liquor carry-over in vent vapors. The vent vapors are
passed through two-stage cyclone separators and condensed in a shell and tube condenser using mill
water. The water is heated from 40 Degrees C.to 85 Degrees C. The poly-hydrolysate (PH) liquor
from the draining operation is also flashed in a cyclone and the flash vapors are condensed, thus
recovering maTinnim possible heat without allowing the liquor to form resinous deposit.
5.2 Scale of Operation: Not reported
5.3 State of Development: The clean technology is fully implemented.
5.4 Level of Commercialization: The clean technology is fully commercialized.
5.5 Balances and Substitutions: Use of live steam was reduced by about 48 T/day.
6.0 Economies'11
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
The heat recovery is in the form of hot water which is used in the bleach plant, and has resulted in
reduction in use of live steam of about 48 ton/day. This is equivalent to about Rs. 62/ton pulp and savings
of Rs. 3.9 million/year.
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8.0 Obstacles, Problems and/or Known Constraints
The liquor has a typical characteristic of forming resinoces deposits but this problem was rectified.
9.0 Date case study was performed: Not reported
10.0 Contacts and Citation
10.1 Types of Source Material: Unpublished
10.2 Citation: Mr. Shailendra Jain, Senior Executive President, Harihar Polyfibers (GRASIM),
' Karnataka, India.
10.3 Level of Detail of Source Material: Additional information is available in the source document.
10.4 Industry/Program Contact and Address: Mr. Shailendra Jain, Harihar Polyfibers (GRASIM),
Karnataka, India.
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Lynn L. Curry, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Thermal waste
11.2 Process Type/Waste Source: Pulp, sulphate process, textile industry, SIC 2299
11.3 Waste Reduction Technique: Heat recovery, cyclone separators
11.4 Other Keywords: India
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Thermal Waste, Pulp, Sulphate Process, Textile Industry, SIC 2299, Heat Recovery, Cyclone
Separators, India
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Installation of dewatering booster presses reduces oil consumption during manufacture of
dissolving grade paper and improves pulp quality by avoiding "burnouts."
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Harihar Polyfibers, GRASIM, Karnataka, India.
4.0 Clean Technology Category: ,
Technology Principle: This technology involves equipment modification to reduce oil consumption and hot
air temperature.
5.0 Case Study Summary
5.1 Process and Waste Information: In the finishing steps of manufacture of dissolving grade pulp, at
Harihar Polyfiber, the pulp is dewatered, flash dried, baled and packed. The mechanical
dewatering was done to about 38% of dry content, then the pulp was dried further to 70% of dry
content using hot air at 300 Degrees C, generated by burning fuel oil.
In order to reduce the oil consumption and temperature of the hot air, two dewatering booster
presses were installed in series after the existing dewatering presses running in parallel. This
improved the dryness of pulp to +50 % and the temperature of the hot air could be brought down
to 200 Degrees C.
5.2 Scale of Operation: Not reported
5.3 State of Development: The clean technology is fully implemented.
5.4 Level of Commercialization: The clean technology is fully commercialized.
5.5 Balances and Substitutions: Improvement in dryness content of pulp by 50% and temperature of
hot air is reduced from. 300 Degrees C to 200 Degrees C.
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Economic benefits were a savings of Rs. 3.5 million/year by reducing fuel oil consumption by about 14
kg/tonne of pulp. Furthermore, an improvement in pulp quality resulted by avoiding the "burnouts" due
to higher temperatures of hot air.
Environmental benefits include reduction in fuel oil consumption.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date case study was performed:- Not reported
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10.0 Contacts and Citation
10.1 Types of Source Material: Unpublished
10.2 Citation: Mr. Shailendra Jain, Senior Executive President, Harihar Polyfibers (GRAS1M),
Karnataka, India.
10.3 Level of Detail of Source Material: Additional information is available in the source document.
10.4 Industry/Program Contact and Address: Mr. Shailendra Jain, Senior Executive President, Harihar
Polyfibers (GRASIM), Kamataka, India.
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Lynn L. Curry, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Not reported.
11.2 Process Type/Waste Source: Textile industry, SIC 2299
11.3 Waste Reduction Technique: Energy conservation
11.4 Other Keywords: India
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textile Industry, SIC 2299, Energy Conservation, India
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Improved washing equipment for pollution load reduction in a synthetic fiber mill results in
reduced steam and chemical requirements.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Harihar Polyfibers, GRASIM, Kamataka, India
4.0 Clean Technology Category
Technology Principle: Process/equipment modifications to reduce energy and chemical consumption.
5.0 Case Study Summary
5.1 Process and Waste Information: Use of a three-stage counter-current brown stock pressure washer
at a pulp mill resulted in high alkali loss with the brown pulp stock, carry-over of liquid impurities
with the pulp, and high chlorine consumption in the bleach stage. This contributed to the effluent
load by way of discharge of.chlorinated organic compounds, color, COD, etc. The spent liquor
recovered from the washing plant was dilute, requiring more steam for evaporation. The
introduction of a fourth-stage pressure wash in series with the previous three resulted in reduction
in steam requirements and in chemical requirements, and in alleviation of problems caused by alkali
loss and carry-over of lignin compound along with the pulp.
5.2 Scale of Operation: Not reported
5.3 State of Development: Technology is fully implemented
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions:
Material Category
Waste Generation:
Color
Chlorinated organic
compounds
COD
Feedstock Use:
Chlorine
Alkali
Water Use:
Energy Use:
Steam
Quantity Quantity
Before After
N/A 40% reduction
N/A 14% reduction
N/A 22% reduction
N/A 6.5 kg/ton reduction
N/A 3.0 kg/ton reduction
N/A N/A
N/A 0.2 ton/ton reduction
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6.0 Economics
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Reduction in steam requirements for evaporators, resulting in savings of Rs. 3.0 million/year. Reduction
in chemical requirements resulted in savings of Rs. 0.8 milliom/year for chlorine and Rs. 19 million/year
for make-up alkali.
8.0 Obstacles, Problems and/or Known Constraints
Not reported.
9.0 Date case study was performed: Not reported
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished material
10.2 Citation: Mr. Shailendra Jain, Senior Executive President, Harihar Polyfibers (GRASIM),
Karnataka, India
10.3 Level of Detail of Source Material: Additional information is available in source document.
10.4 Industry/Program Contact and Address: Mr. Shailendra Jain, Senior Executive President, Harihar
Polyfibers (GRASIM), Karnataka, India
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Isaac Diwan, Science
Applications International Corporation, 760Q-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Synthetic fiber mill
11.3 Waste Reduction Technique: Equipment modification
Keywords: Textiles, Wastewater, SIC 2299, Synthetic Fiber Mill, Equipment Modification
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Paper Mills
***** DOCNO: 450-003-A-362*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL St. FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Kruger Inc. recovers Whitewater at their newsprint mill and reduces
wastewater discharge and energy costs.
Paper and Allied Products/SIC 2621
Kruger, Inc.
Bromptonville, Quebec
A series of modest modifications to a newsprint mill have achieved recovery
of significant amounts of lean and clear wastewaters that had been
discharging to the sewer. Lean Whitewater from the company's three paper
machine presses are collected by gravity flow in a reservoir beneath the
machines. It is then pumped through a Sweco filter, where 90% is used for
dilution of stock and 10% is sent to the clarifier. Clear Whitewater is now
used instead of heated freshwater on the paper machine showers.
Whitewater from newsprint mill
Wastewater
Water
Not reported
Not reported
Not reported
Not reported
$580,000/year
1.8 tons/day fiber recovered, which represents $80,000/year. Recovered .
lean Whitewater led to $500,000/year savings.
Discharges to sewer significantly reduced.
Efforts to recycle wastewaters, previously discharged to the sewer, have
greatly reduced the volume of waste generated, and allow for recycling of
fiber feed material.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 64.
Paper and Pulp, Filtration, Wastewater, Recycling, Recovery, SIC 2621
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The effluent-free newsprint mill achieved through treatment and inplant reuse.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
Pi-Consulting Ltd, MyyrmaenraM 2, P.O.Box 31, SF-016101 Vantaa, Finland, phone +358 0 530 91,
telex 122905 pihki sf, telefax +358 0 563 2003.
4.0 Cleaner Technology Category
Paper mill process water is treated and reused. No effluent is discharged from the mill. Some water is
driven off in the flue gases from the bark fired boiler and in the drying air from the paper machine hood
like in all existing mills.
5.0 Case Study Summary
5.1 Process and Waste Information: A typical newsprint mill using mechanical pulp as raw material
consumes 5-15 m3 of water per tonne of paper. Effluent is normally treated biologically before
being sewered into the recipient.
A newsprint mill with no process effluent has been designed by using the Pl-Consulting's RAM!
simulation program. In the designed paper mill, 7 m3 of water per tonne of paper will be treated
and reused. Three water treatment methods were employed: evaporation, ultrafiltration and reverse
osmosis.
Raw materials and production of the paper mill are conventional. Process water is treated by
evaporation and ultrafiltration and used again, no effluent is discharged from the mill.
Concentrates from evaporation and ultrafiltration are burned along with bark in the bark boiler.
Inorganic salts will dissolve in the flue gas scrubbing water. This water is then treated first by
ultrafiltration and then by reverse osmosis. The salts are finally concentrated and taken away from
the mill.
The production at the pulp mill and the paper mill take place as normal. To balance the water
circulation to the output of the pulp lines and the paper machine, storage tanks of a total volume
of 17,000 m3 are needed:
5.2 Scale of Operation: The capacity of a new newsprint mill is 250,000 tonnes per year. The total
amount of effluent water treated biologically is about 12,000 m3 of water per day. In the designed
mill 2,600 m3 of process water are treated by evaporation and stripping. Another 2,400 m3 of
water are treated by ultrafiltration. Some 160 mVd of the flue gas scrubbing water is treated by
reversed osmosis.
5.3 Stage of Development: All three water treatment methods are today implemented in other uses.
The quantities of water to be treated are estimated from experience and calculated from the process
simulation program.
The study work is continued with pilot scale equipment in a Finnish pulp and paper mill. The work
is sponsored by the Technology Development Centre Finland, EUREKA status for the project has
been requested. The project title is: Improved water reuse in paper industry.
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5.4 Level of Commercialization: Equipments for all three water treatment methods are commercially
available. Pilot scale studies are under way for paper mill applications.
6.0
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
Economics*
Quantity Before
5-15 m3 water/t paper
Boiler ash
N/A
5-15 m3/t paper
3-4 MWh/t paper
Quantity After
None
Boiler ash+some salt
N/A
0.6 m3/t paper
3.1-4.1 MWh/t paper
6.1 Investment Costs: The estimation shows that an effluent-free greenfield paper mill would cost USD
390 million, making it only about 1 % more expensive than a conventional greenfield paper mill
with a modem external treatment plant for effluent.
Evaporation plant for 2,600 m3/d costs USD 4 million, ultrafiltration plant for 2,400 nrVd costs
USD 1 million and reversed osmosis plant for 160 nrVd costs USD 1 million.
6.2 Operational and Maintenance Costs: The difference in operating costs arises from differences in
water treatment costs. The operating costs for the conventional mill having a biological treatment
plant are about USD 3 lower per tonne of paper. It is assumed that the steam required for
evaporation is produced by burning oil.
6.3 Payback Time:
7.0 Cleaner Production Benefits
An effluent-free paper mill benefits from the small quantity of fresh water needed allowing the mill to be
built even in forest areas. A mill without any effluent could also be built near big cities where recycled
fibre can be used as raw material.
8.0 Obstacles, Problems and/or Known Constraints
There are still some questions to be answered before the water circulation in a paper mill can be totally
closed. Investigations should be done with pilot scale equipment in existing mills. The questions are:
What is the most economical way of treating the water before evaporation and ultrafiltration? How should
cleaner waters be treated? What kind of concentrates are formed in evaporation and ultrafiltration and what
is the best way of burning them?
9.0 Date Case Study Was Performed: The case study was performed as a part of SYTYKE, the Environmental
Research and Development Programme for the Finnish Forest Industry and reported June llth 1991.
10.0 Contacts and Citation
10.1 Type of Source Material: A research programme report and an article.
10.2 Citation: (1) A SYTYKE research programme report, will be published in 1993, in Finnish,
summaries in English, German and Swedish; (2) Jantunen, E., Lindholm, G., Lindroos, C.,
Paavola, A., Parkkonen, U., Pusa, R. and Soderstrom, M., The effluent-free newsprint mill,
Paperi ja Puu - Paper and Timber, Vol. 74, No.l, 1992, pp. 41-44.
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10.3 Level of Detail of the Source Material: Companies manufacturing evaporation and ultrafiltration
units are providing more information.
The investigation was conducted using the RAMI process simulation program developed by PI
Consulting Ltd. More information about the possibilities of simulating all pulp and paper processes
is available.
10.4 Industry/Program Contact and Address: Pi-Consulting Ltd, Myyrmaenraitti 2, P.O.Box 31, SF-
016101 Vantaa, Finland, phone +358 0 530 91, telex 122905 pihki sf, telefax +358 0 563 2003.
10.5 Abstractor Name and Address: Esko Jantunen, Pi-Consulting Ltd, Myyrmaenraitti 2, P.O.BoxSl,
SF-016101 Vantaa, Finland, phone +358 0 530 91, telex 122905 pihki sf, telefax +358 0 563
2003.
11.0 Keywords
11.1 Waste type: Effluent water.
11.2 Process type/waste source: Mechanical pulp, Paper mill.
11.3 Cleaner Production Technique: Evaporation, Ultrafiltration, Reversed osmosis.
11.4 Other Keywords: Newsprint mills, Pulp washing, Process simulation.
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Effluent water, Mechanical pulp, Paper mill, Evaporation, Ultrafiltration, Reversed osmosis, Newsprint
mills, Pulp washing, Process simulation.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Enzymatic pitch control in the papermaking process.
2.0 SIC/ISIC Code: 13411.
3.0 Name and Location of Company:
Jujo Paper's Ishinomaki mill, Japan; Jujo Paper's Yarsushiro mill, Japan; other companie's mills.
4.0 Cleaner Technology Category
Enzyme is introduced in the papermaking process to solve pitch problems. The enzymatic pitch reduction
reduces the side effects of conventional pitch reduction by seasoning during storage. Those are yield loss
and brightness reduction. .
5.0 Case Study Summary
5.1 Process and Waste Information: Jujo Paper's Ishinomaki mill uses 10-30% red pine groundwood
to produce newsprint and telephone directory paper. In controlled trials, employing 50 % unseasoned
wood, Resinase A 2X was added prior to the disk refiners located before the mixing chest. Most
of the effect is believed to occur in the first of two intermediate chests located between the refiners
and the mixing chest, where conditions were controlled at 4% consistency, 40-50°C and a pH value
of 6.5-7.0.
For newsprint, the Resinase A 2X addition level was 0.5 kg/bone-dry ton pulp and a residence time
of 30 minutes was allowed. For YTD (Yellow telephone directory), enzyme dosage was reduced
to 0.38 kg/bone-dry ton of pulp and the residence time increased to three hours.
The results show that the produced paper, which has been treated with the enzyme, contains less
pitch and that the number of spots and holes in the paper is reduced. These improvements were
achieved while cutting the amount of fine talc added by one third. Fine talc is usually added as a
control agent to eliminate the pitch problems.
5.2 Scale of Operation: Industrial scale.
5.3 Stage of Development: This technology is used in the actual papermaking process.
5.4 Level of Commercialization: The technology is commercially available. The Novo Nordisk's
enzyme Resinase A 2X was used.
5.5 Material/Energy Balances and Substitutions: The enzyme is mixed with mechanical pulp slurry in
the conventional mill fiber line. Therefore, no additional fresh water is required. Energy
requirement increase is just for mixing and very small. Pitch is hydrolyzed to fatty acids that are
retained on pulp fiber. Therefore, no waste material is generated. These characteristics are
summarized below.
Material Category
Waste Generation:
Water Use:
Energy Use:
Quantity Before
none
no increase
very small increase
Quantity After
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6.0 Economics
: 6.1 Investment Costs: The investment of a blending tank and a mixer.
6.2 Operational and Maintenance Costs: Resinase A 2X costs 3800 yen/kg and the dosage of the
Resinase A 2X is 0.3-0.5 kg/bone-dry pulp ton.
6.3 Payback Time: The costs are paid back by improved paper machine operation and product quality
with higher fresh log ratio in wood supply, which means less cost in wood yard operation.
7.0 Cleaner Production Benefits
; See 4.0.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study was Performed:
1987-88 Laboratory research
1989 March First mill trial in Ishinomaki mill
1989 May-July Long run mill trial in Ishinomaki mill
1990 March-July Long run mill trial in Yatsushiro mill
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles and conference proceedings.
10.2 Citations:
(1) Grant, R., Enzyme technology - First mill-scale trials get underway, PPI, June 1991, pp. 61-63.
(2) Irie, Y., Matsukura, M., Usui, M. and Hata, K., 1990 Papennakers Conference: 1-10(1190).
(3) Hata, K. et al., 1992 Papermakers Conference: (1)73-79(1992).
(4) Hata, K. et al., JAPAN TAPPI Journal: 905-921 Aug. 1992.
(5) Hata, K. et al., TAPPI Journal, vol.74, no.4, 117-122, April 1992.
10.3 Level of Detail of the Source Material:
10.4 Industry /Program Contact and Address: Kunio Hata, Managing Director, R & D, Jujo Paper Co.,
Ltd., Shin-Yurakucho Bldg., 12-1, Yurakucho 1-chome, Chiyoda-ku, Tokyo, Japan.
Tokue Iwatsu, President, Jujo Research Co. Ltd., Jukkai Bldg., 5-24, Oji, 5-chome, Kitaku,
Tokyo, 114, Japan.
10.5 Abstractor Name and Address: Mrs Virve Tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-Q2151
Espoo, Finland, Tel. +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf.
11.0 Keywords
11.1 Waste type:
11.2 Process type/waste source: Newsprint mill, Mechanical pulp containing paper.
11.3 Cleaner Production Technique: Pitch reduction, Enzymatic pitch control.
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11.4 Other Keywords: Biotechnology, Enzyme.
11.5 Country Code: Japan.
12.0 Assumptions
13.0 Peer Review
Yes.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Newsprint mill, Mechanical pulp containing paper, Pitch reduction, Enzymatic pitch control,
Biotechnology, Enzyme.
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Dry forming of paper web
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
United Paper Mills Ltd, Walkisoft factory, Kotka, P.O.Box 81, SF-48101 KOTKA, Finland, tel.+358-52-
15440, telex 53132 UPMWF SF.
4.0 Cleaner Technology Category
The process is non-polluting, there are no wastewater problems, and therefore, the mill can be located
either close to consumers in an urban location or near the sources of raw material.
5-0 Case Study Summary
5.1 Process and Waste Information: The dry forming method can in principle be divided into the
following phases: defibration of raw material, forming, binder application, curing, and finishing.
The main raw material, mostly wood pulp, is defiberized in a hammer mill. After this, the fibres
are transported by means of a fan to the forming section.
Each former consists of two perforated drums rotating inside the forming head. The fibres circulate
horizontally between the drums. The accepted fibre material is formed onto the moving forming
wire by suction. After forming, the web is led through heated compactor and embosser rolls.
In the third phase, a binder solution is sprayed onto the web. The application is made separately
on both sides of the web, each application being followed by through-drying.
Full strength is achieved during the curing as the binder is cross-linked. The curing is also
performed in a through-dryer. To improve the final properties, the web is led through a finishing
calender.
In the conventional process, most of the water that is drained from the sheet in the wire section and
pressed off in the press section is recycled. Some of it is extracted from the process and led back
into the watercourse. The evaporated water has to be replaced by fresh water.
In the dry forming process, the fresh water demand is only 0.8 litres per one kilogram produced
material (air dry). It is totally used to dilute the binder. The dry forming process creates neither
wastewater nor effluent gases.
5.2 Scale of Operation: The work has progressed from a semicommercial pilot machine to a full scale
production unit.
5.3 Stage of Development: Fully implemented.
5.4 Level of Commercialization: The technology is commercially available.
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6.0
5.5 Material/Energy Balances and Substitutions:
Material Category Quantity Before
Waste Generation: N/A
Feedstock Use: N/A
Water Use: N/A
Energy Use:
N/A
Quantity After
N/A
N/A
0.8 I/kg AD
product
N/A
Economics*
6.1 Investment Costs: Investment cost of a dry forming machine is rather low and the economically
profitable size of the production plant is small. The capacity of the plant can be enlarged gradually
according to market demand.
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
Dry formed materials have unique absorption and wet strength properties. They are nonabrasive, soft and
feel like textiles. The products are suitable for different kinds of towelling and wiping, in health-care,
hygiene and for table settings.
The dry forming machine can be located either near consumers or near raw material sources. It does not
emit waste water or stack gases.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed: United Paper Mills Ltd has been actively involved in the development
of the dry forming process since the late 1970's. The first production unit at the Kotka mill started up at
the beginning of 1985.
10.0 Contacts and Citation
10.1 Type of Source Material: A report on technologies from Finland.
10.2 Citation: Environmental high-technology from Finland, Prepared by Mexpert Consulting Engineers
Ltd. for the Ministry of the Environment, Helsinki 1987, pp. 33- 36.
10.3 Level of Detail of the Source Material: Additional information on the paper properties is available
in the source material.
10.4 Industry/Program Contact and Address: Material Business: United Paper Mills Ltd, Walkisoft
factory, Kotka, P.O.Box 81, SF-48101 KOTKA, Finland, tel.+358-52-15440, telex 53132 upmwf
sf, telefax +358-52-84360.
Machinery: United Paper Mills Ltd, Walkisoft Engineering, Valkeakoski, P.O.Box 40, SF-37601
VALKEAKOSK1, Finland, tel. +358-37-7111, telex 22316 ypkot sf, telefax +358-37-43814.
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10.5 Abstractor Name and Address: Mrs Virve tulenheimo, MSc, Research Engineer, Technical
Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205, SF-02151
Espoo, Finland, Telephone -1-358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha sf
.11.0 Keywords
11.1 Waste type: Paper mill effluent
11.2 Process type/waste source: Paper production
11.3 Cleaner Production Technique: Dry forming, Effluent-free paper mill
11.4 Other Keywords:
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Paper mill effluent, Paper production, Dry forming, Effluent-free paper mill,
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***** DOCNO: 400-028-A-217 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Wastewater treatment and recycling reduces discharge of pollutants and
requirements for virgin chemicals.
Manufacturing of Paper and Paper Products/ISIC 3411
Ministere de PEnvironment et du Cadre de Vie
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The company manufactures paper with the recovery and valorization of
manufacturing effluents. The manufacturing effluents are separated two
distinct ways. There is a physical chemistry treatment and a
coagulation-flotation with the introduction of pressurized water and
poly-electrolyte. The recovered raw materials are in part immediately
re-integrated into the paper production process, the rest being held for later
use or sale. Purified effluents are discharged into the river by way of a
sewer.
Wastewater
The manufacturing water is purified before being discharged into the river.
Pollution results solely from cooling water. There are 3 kg of suspended
and oxidizable matter per ton of paper manufactured, against 18.1 kg in the
standard treatment technique.
Water
(1980 Francs)
F 800,000
F 1.8/ton paper produced
Not reported
Not reported
Not reported
Not reported
Not reported
Reduces requirements for virgin chemicals.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Water Closure System in Paper Mills,"
Monograph ENV/WP.2/5/Add 28.
Paper, ISIC 3411, Closed-Loop Wastewater
2-336
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***** DOCNO: 400-089-A-256*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Closed-water system eliminates wastewater generation from paper-board
facility.
Manufacture of Pulp, Paper and Paper-board/ISIC 3411
Paper-board making with closed water systems. Water consumption in a
hypothetical mill practicing no recycling of water would be 200 - 300
m3/ton paper produced. Conventional processes recycle a portion of their
process waters, but also introduce freshwater in some process areas. A
closed system blends in freshwater only as a make-up or in order to dilute
some component that might otherwise restrict recycling.
Primary pulps and/or secondary fibers, process additives, product quality
additives (clay, chalk), water, 30 GJ energy for each ton of paper
generated
Steam, no liquid or solid effluent discharge
Water vapor
$457,000
Not reported
7.5 months excluding additional operating costs
10 British Pounds/ton primarily in waste treatment
Not reported
Wastewater production is eliminated. The amount of solid residuals
generated is decreased from 6% (64 kg/ton) to 1 percent of waste
production.
Recycling of process waters and recovery of additional 5% of suspended
solids is the benefit offered by this technology. Practical problems,
including product quality, were incurred during closing-up of the water
system and are therefore a significant deterrent to a mill considering
implementation.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Paper/board Making With Closed Water
Systems," Monograph ENV/WP.2/5/Add89.
Pulp, Paper, Wastewater Recovery, Recycling, ISIC 3411
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****DOCNO: 400-091-A-258*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
ZIMPRO process recovers filler clay for reuse in paper production.
Pulp Paper and Paper Board/ISIC 3411
The ZIMPRO process for disposal of wastewater treatment sludge in the
paper and board industry recovers the filler clay by wet air oxidation of the
sludge. The sludge is mixed with biological sludge and continuously
oxidized by compressed air at 250-350 degrees centigrade and 120-150 bar.
After the reaction, the filler clay (kaolin) is separated and cleaned for reuse
in paper production.
Sludge from treatment plant, electrical energy, fuel oil, flocculant, water
Wastewater from the settling tanks containing small amounts of acetic acid
.and other organics are added to the biological water treatment plant. The
filler clay which is re-used in the paper production.
Water
(For Oxidizing 16.5 ton/dry sludge in 1977)
750,000 Swiss francs
560,000 ft/year
Not reported
430,000 fir/year operating savings over incineration, 110,000 increase over
lagooning
Not reported
400,000 fr/year savings due to kaolin recovery
The recovered filler clay can be re-used in paper production, paying for the
operating cost of the plant. The disposal of the sludge via incineration or
lagooning is eliminated.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Filler Clay Recovery by Wet Air Oxidation
of Sludge (Zimpro Process)," Monograph ENVAVP.2/5/Add91.
Pulp, Paper, Waste Recovery, ISIC 3411, Wet Air Oxidation, ZIMPRO,
Kaolin Clay
2-338
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***** DOCNO: 400-075-A-249*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
CSM-Biothane process treats wastewater to reduce sludge generation and
produce methane gas for input to the production process.
Manufacture of Food, Beverages and Tobacco/ISIC 31 Manufacture of
Paper and Paper Products/ISIC 34
The CSM-Biothane U.A.S.B. process for anaerobic wastewater treatment
treats organic wastewater generated during processing of food and paper
related materials. This new technology consists of a digester where settling
occurs under anaerobic conditions. Methane gas is produced as a by-product
and can be used as energy for input to the production process.
Organic wastewater, sludge
Anaerobic wastewater sludge consisting of 2 to 20% carbon compounds, all
nitrogen as ammonia
Organic wastewater sludge
125,000 to 250,000 Dutch guilders
0 to 500 Dutch guilders (20% of investment costs)
Not reported
375,000 to 1,250,000 Dutch guilders
25 to 50% reduction in need for additional nutrients (P and N)
Reduces production of surplus sludge by 80 to 90%
The CSM-Biothane process for anaerobic wastewater treatment reduces the
quantity of sludge generated by 80% to 90%, and also produces methane
gas which can be used as a substitute for energy in a production process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "CSM-Biothane U.A.S.B. Process for
Anaerobic Waste Water Treatment," Monograph ENV/WP.2/5/Add75.
Food Processing, Paper, Energy Recovery, Sludge, Wastewater Treatment,
ISIC 31, ISIC 34
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TEXTILE
Synthetic Textiles
Wool Manufacturing
Cotton Production
General Textile
-------
-------
Synthetic Textiles
***** DOCNO: 450-003-A-378*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Recycling spent nylon hosiery dyebaths reduce disposal costs and raw
material purchases.
Rubber and Plastics/ISIC 15, ISIC 16
Dominion Textiles, Inc.
Valleyfield, Quebec
. A pilot operation was established to recycle spent nylon hosiery dyebaths
containing disperse dyes and chemical auxiliaries (scouring, levelling and
wetting agents). The dyebaths are pumped from the rotary drum dying
machine to a holding tank for analysis and reconstitution with dyestuff. An
average of 30 batches can be dyed before discharge.
Dyes, chemical auxiliaries
Spent dyes and chemicals
Liquid
$28,441 for conversion and analytical equipment (1980)
Wet processing costs decreased by $0.044/kg
Not reported
$12,240/year
19% reduction in dye consumption, 35% in auxiliaries and 57% in energy.
Spent dyes and chemicals no longer require disposal.
Contaminated dyes and chemicals are being recycled, reducing the volumes
disposed, in addition to raw material and disposal costs.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 91.
Textiles, Dye, Recycling, Recovery, Nylon, ISIC 15, ISIC 16
2-340
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DOCNO: 400-121-A *****
1.0 Headline: Zinc recovery in the rayon industry in Netherlands.
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: Enka B.V., Velperweg, Kleefsewaard at Amheim, Netherlands
4.0 Clean Technology Category: This case study addresses recovery of zinc
5.0 Case Study Summary:
5.1 Process and Waste Information: The main production steps in the rayon industry are (1) the
reaction of cellulose with sodium hydroxide, followed by pressing and grinding; (2) the reaction
of sodium-cellulose with carbon disulfide; (3) the creation of a solution of reaction product in water,
called viscose; (4) the spinning of viscose by injection through a spinning head into a spinning bath,
where the viscose is transformed into cellulose yarn by coagulation; and (5) finishing of rayon tire
cord by washing, lubrication, and drying.
During the spinning process, zinc sulphate is used to slow down the formation of the yarn. This
is necessary in order to obtain the desired strength and elongation of the yarn. The wastewater
from the spinning process contains mainly sulfuric acid, sodium sulphate, and zinc salts. This
wastewater is treated in the biological wastewater treatment plant. Removal of zinc** is effected
by precipitating it to form inert zinc sulfides. The biological sludge containing this zinc sulfide is
dumped on the land. For the wastewater, the discharge draft standard for zinc in some areas of
the Netherlands is 20 kg/day. The maximum allowable amount of zinc in any given sample of
wastewater effluent is 3 mg/liter. Over a 24-hour period the maximum allowable zinc content in
the wastewater effluent is 2 mg/liter.
The low-waste technology concerns the recovery and recycling of zinc from the acid effluent of the
rayon spuming process. The zinc+* containing acid effluent is treated with a mixture of
D.E.H.P.A. (10%) and solvesso 150 (90%). The ratio of acid effluent to organic solvent is
generally less than one. Treatment occurs in a tank fitted with agitators. The dispersed water and
organic solvent is transported to a separation tank in order to obtain separation between water and
the organic phase. The extraction process is carried out in three steps with counter-flow of the
effluent and the organic solvent. The reaction product of zinc** and D.E.H.P.A. dissolves in the
organic phase. This organic phase has to be stripped in order to recover the zinc * * .
In order to obtain high efficiency of zinc* * removal, the pH of the water phase must be controlled
by addition of sodium hydroxide. During the first extraction step the pH is greater than 2.8 and
afterwards it is greater than 3.0. The zinc + + removal efficiency is generally more than 98%. The
zinc-free water phase is neutralized and charged together with 10 times the amount of caustic
wastewater in the wastewater treatment plant. The effluent from the wastewater treatment plant is
dumped together with three times the amount of other wastewater into open water.
To recover the zinc** from the organic extraction solvent, the solvent is stripped with a
water-based solution of sulfuric acid (20%) and a flocculent. This is, however, a one-step process.
During stripping, the zinc** is re-worked as zinc sulphate. It dissolves in the waster phase. This
solution is used again in the spinning process. The addition of a flocculent is essential in order to
obtain high efficiency of zinc+* recovery and to prevent large losses or organic solvent. This
flocculent neutralizes the cation-active substances. The zinc** recovery efficiency is about 100%.
2-341
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6.0
7.0
8.0
9.0
10.0
11.0
(*)-
5.2
5.3
5.4
5.5
Scale of Operation: The plant maximum capacity for treatment is 40 cubic meters of effluent per
hour.
Stage of Development: The technology is fully implemented.
Level of Commercialization: Unknown
Material/Energy Balances and Substitutions: Figures based on tone of rayon tire cord production
in the effluent discharge.
Economics*
6.1
6.2
6.3
Investments Costs: While the total investment for the conventional process is 2,000,000 Fl, the
investment for the low-waste technology is 5,600,000 Fl. The cost of rayon tire cord per year
increases from 70 Fl for the conventional method to 85 Fl for the low-waste technology. Zinc
recovery results in savings of 225,000 Fl per year.
Operational & Maintenance Costs: Unknown
Payback Time: Unknown
Cleaner Production Benefits: Because the zinc removal efficiency is high, there are economic benefits as
well as regulatory benefits.
Obstacles, Problems, and/or Known Constraints: Not available.
Date Case Study Was Performed: 1982
Contacts and Citation
10.1 Type of Source Material: United Nations document.
10.2 Citation: United Nations Economic and Social Council, Economic Commission for Europe,
Compendium on Low- or Non-Waste Technology, Monograph ENV/WP.2/5/Add. 121, May 1985.
10.3 Level of Detail of Source Material: Unknown
10.4 Industry/Program Contact and Address: Unknown
10.5 Abstractor Name and Address: The information in this case study was derived from abstracts
provided by the United Nations Environment Program (Paris). This abstract was prepared directly
from the abstract without access to the document cited. Mary L. Wolfe, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
Keywords
11.1 Waste type: Wastewater
11.2 Process Type/Waste Source: Textile Mill Products, SIC 22
11.3 Waste Reduction Technique: Wastewater reduction, reuse, recovery
Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and
other factors.
Keywords: Wastewater, Textile Mill Products, SIC 22, Wastewater Reduction, Reuse, Recovery
2-342
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Wastewater reuse in a synthetic textile mill in Bombay, India.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Orkay Textile Processors, Said Naka, Andheri (East), Bombay, India
4.0 Clean Technology Category
Technology Principle: This technology involves treated wastewater reuse at a textile unit where the entire
volume was reused.
5.0 Case Study Summary '
5.1 Process and Waste Information: Wastewater reuse was implemented at a textile unit in Bombay
processing 30,000 meters/day of polyester and polyviscose piece dyed shirting and suiting. The total
quantity of wastewater discharged including floor washing was about 900 cubic meters per day.
The wastewater was treated in the scheme such as equalization and neutralization, chemical assist
(using alum) sedimentation, pressure sand filter and a fluidized polishing reactor based on activated
carbon. The entire volume of treated wastewater was reused in the process.
5.2 Scale of Operation: Daily production of 30,000 meters/day of polyester and polyviscose piece and
fiber dyed shirting and suiting.
5.3 State of Development: This clean technology is fully implemented.
5.4 Level of Commercialization: This clean technology is fully commercialized.
5.5 Balances and Substitutions: Entire quantity of wastewater was recycled.
Economics*
6.0
7.0
6.1 Investment Costs: Civil capital costs (Rs. 200,000) plus mechanical capital costs (Rs. 700,000)
totalled Rs. 900,000 for investment costs.
6.2 Operational and Maintenance Costs: Costs of chemicals per day (Rs. 1,700) plus power costs per
day (Rs. 300) plus manpower costs per day (Rs. 100) brought the total O & M costs to Rs. 2,100
per day.
6.3 Payback Time: For 300 working days in a year, the pay back period was calculated to be 9
months.
Cleaner Production Benefits
Environmental and economic benefits include reduced consumption of fresh water and a net savings of Rs.
4,300 per day since there was a reduction in costs for purchase of 800 cubic meters of fresh water at Rs.
8 per cubic meter.
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8.0 Obstacles, Problems and/or Known Constraints
The plant was commissioned in 1983-84. Recently operational problems were found in the fluidized
column if activated carbon.
9.0 Date case study was performed: 1984
10.0 Contacts and Citation
10.1 Types of Source Material: Conference proceeding.
10.2 Citation: Handa, B.K. "Wastewater Management in a Synthetic Textile Industry," All India
Workshop on Environmental Management of Small Scale Industries, July 22-23, 1989, Nagpur.
10.3 Level of Detail of Source Material: Additional information is available in the source document.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Lynn L. Curry, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Textile industry, SIC 2299
11.3 Waste Reduction Technique: Wastewater reuse
11.4 Other Keywords: Water reuse, fresh water
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textile Industry, SIC 2299, Wastewater Reuse, Treated Wastewater, Fresh Water
2-344
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Recovery and reuse of solid waste from a synthetic textile industry.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Harihar Polyfiber, GRASIM, Kamataka, India
4.0 Clean Technology Category
Technology Principle: This technology involves recovery of solids in the effluent and selling the recovered
material.
5.0 Case Study Summary
5.1 Process and Waste Information: At this facility the rejects from the last centri-cleaner stage were
sent to the sewer. This resulted in the jamming of the primary clarifier sludge screen and higher
suspended solids in the effluent as well as fiber loss. Also, the underflow sludge from the primary
effluent clarifier was very dilute and the disposal of the same was very difficult. In the new process
the solids were slurryied and passed through a vibrating screen and finally dewatering to 35 % dry
content. This was then bagged and sold to board and cellulose powder manufacturers.
To alleviate the problem of the dilute underflow sludge, the sludge was dewatered to 35% dry
content by passing it through a vibrating screen and screw press and then bagged and sold to board
manufacturers and for packing purposes.
5.2 Scale of Operation: Not reported
5.3 State of Development: The clean technology is fully implemented.
5.4 Level of Commercialization: The clean technology is fully commercialized.
5.5 Balances and Substitutions: Not reported
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Savings of 0.3 million Rs./year were realized from the sale
of the water.
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Economic benefits were estimated to be Rs. 0.3 million/year from the wastes sales.
8.0 Obstacles, Problems and/or Known Constraints
Not reported
9.0 Date Case Study Was Performed: Not reported
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10.0 Contacts and Citation
10.1 Types of Source Material: Unpublished
10.2 Citation: Mr. Shailendra Jain, Senior Executive President, Harihar Polyfibers (GRASIM),
Kamataka, India.
10.3 Level of Detail of Source Material: Additional information is available in the source document.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Lynn L. Curry, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Textile solid wastes, sludge
11.2 Process Type/Waste Source: Textile Industry, SIC 2299
11.3 Waste Reduction Technique: By-product recovery, reuse
11.4 Other Keywords: India
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textile Solid Wastes, Sludge, Textile Industry, SIC 2299, By-Product Recovery, Reuse, India
2-346
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Recycling of process waste to reduce chemical requirements in a synthetic fiber industry.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Harihar Polyfibers, GRASIM, Karnataka, India.
4.0 Clean Technology Category
Technology Principal: This technology involves recycling of HC1 and caustic soda.
5.0 Case Study Summary
5.1 Process and Waste Information: At this facility, the cation units were regenerated with HC1 and
the back wash and rinse water were being drained to the effluent plant. The anion unit was
regenerated with alkali (NaOH) and the spent waste was also being drained to the effluent plant.
To recover and recycle HCL and caustic soda, the cation back wash was analyzed and checked for
content of acid and other impurities. This was deemed suitable for neutralizing the effluent from
the staple fiber plant, which was neutralized earlier in the process by addition of fresh HC1. The
anion back wash containing alkali was used for effluent treatment where fresh soda had been used
earlier.
5.2 Scale of Operation: Not reported
5.3 State of Development: The clean technology is fully implemented.
5.4 Level of Commercialization: The clean technology is fully commercialized.
5.5 Balances and Substitutions: Not reported
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Savings of 1.5 million Rs./year in chemical purchases were
realized.
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Reduced mineral acid and alkali (i.e., fresh HC1 and caustic to effluent resulted in a savings of Rs. 1.5
million/year.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date case study was performed: Not reported
10.0 Contacts and Citation
10.1 Types of Source Material: Unpublished.
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10.2 Citation: Mr. Shailendra Jain, Senior Executive President, Harihar Polyfibers, GRASIM,
Karnataka, India.
10.3 Level of Detail of Source Material: Additional information on technical aspects of the industrial
process and cleaner production benefits is provided.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Workgroup, Paris. Reformatted: Lynn L. Curry, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Ion exchange back wash
11.2 Process Type/Waste Source: Ion exchange regeneration, textile industry, SIC 2299
11.3 Waste Reduction Technique: Recycling, reuse
11.4 Other Keywords: Ion exchange, hydrochloric acid, caustic soda
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Ion Exchange Backwash, Ion Exchange Regeneration, Textile Industry, SIC 2299, Recycling, Reuse,
Ion Exchange, Hydrochloric Acid, Caustic Soda
2-348
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Wool Manufacturing
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Closed loop recycle systems for textile effluents.
2.0 SIC Code: 2231, Wool Broadwoven Fabric Mills
3.0 Name & Location of Company: Referred to as "Textile Mills and Pilot Plants" located at University of
Natal, Durban, South Africa
4.0 Clean Technology Category
Recycling, reuse and reclamation: This technology involves the inclusion of treatment/recycle systems for
water and chemical recovery and reuse in textile wet processing operations.
5.0 Case Study Summary
5.1 Process and Waste Information: Individual textile wet processing operations of wool scouring,
desiring and wool/synthetic fiber dyeing result in a large quantity of effluent containing water and
chemicals.
The development of closed loop recycling systems attached to the above mentioned processing
operations is described in this case study. Water and chemical recovery and reuse are discussed.
Several techniques are discussed as well as results of detailed effluent survey techniques to
determine the effluent treatment approach.
Ultiafiltration has been found to be an effective treatment process for recycling wool scouring and
desizing effluents, producing permeates suitable for process reuse with 95% grease rejection.
The results from studies suggest that practical water reuse can only be obtained by a method
referred to as "desuiting" the wool prior to detergent scouring and by the incorporation of an
efficient grease step for die scouring effluent
Ultrafiltration was also found economically attractive for recovery of sizes in cotton textile mills.
The ion exchange and flocculation treatment systems for the wool/synthetic fiber dyehouse effluent
result in a reusable effluent containing the buffer chemicals and recovers the surfactants.
5.2 Scale of Operation: Not reported
5.3 State of Development: Not reported
5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
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7.0 Cleaner Production Benefits
Economic benefits are expected over the conventional end-of-pipe treatment approach, but no specifics were
provided.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date Case Study Was Performed: 1979
10.0 Contacts and Citation
10.1 Type of Source Material: Journal
10.2 Citation: G. R. Groves, C.A. Buckley and R.H. Tumbill. Close Loop Recycle Systems for
Textile Effluents. Journal of Water Pollution Control Federation. Vol. 51, No. 3, March 1979.
10.3 Level of Detail of the Source material: Not reported
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Reformatted: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
'11.0 Keywords
11.1 Waste Type: Wet textile mill effluent
11.2 Process Type/Waste Source: Textile mill products, SIC 2231, wool broadwoven fabric mills,
desizing chemicals, wastev/ater
11.3 Waste Reduction Technique: Effluent recovery, close loop systems, ultrafiltration process
11.4 Other Keywords: Wastewater reduction
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wet Textile Mill Effluent, Textile Mill Products, SIC 2231, Woo! Broadwoven Fabric Mills, Desizing
Chemicals, Wastewater, Effluent Recovery, Closed-Loop Systems, Ultrafiltration Process, Wastewater Reduction
2-350
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
4.0
5.0
6.0
Headline: Reuse of water in a woollen mill.
SIC Code: 2299, Textile Goods, NEC
Name & Location of Company: Shanghai Second Woollen Mills, Shanghai, China
Clean Technology Category
This technology involves the recycling and reuse of wastewater.
Case Study Summary
5.1 Process and Waste Information: Coloured wastewater effluents from two workshops at a woollen
mill were treated using dissolved air flotation and biological towers. Decolonization was achieved
by coagulation and adsorption with activated carbon. After biological treatment and decolonization,
the wastewater was diluted with 20% tap water. This water was used to prepare dyeing liquors.
A neutral dye and a mordant dye were selected. The dyeing recipe was adjusted to account for the
effect of hexavalent chromium ion present in low concentrations in the reuse water.
5.2 Scale of Operation: Not reported
5.3 State of Development: Pilot stage field experiments were performed
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions:
Material Category
Quantity
Before
Quantity
After
120 ?/day
1450 m3/day
420?/day
156 ?/day
300 ?/day
300 nrVday
650?/day
Feedstock Use:
AJ^SOJ,
Activated Carbon
Water Use:
Energy Use:
Electricity
? - Units not provided
Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Operational use of activated carbon reported to cost 12
Yuan/day (1974). An increase in energy use resulted in a net cost increase of 23 Yuan/day.
Wastewater treatment costs increased by 46 Yuan/day. Costs of A12(SO4)3 increased by 13
Yuan/day.
6.3 Payback Time: Not reported
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7.0 Cleaner Production Benefits: Economic benefits were calculated to be 90 Yuan/day (1974) and resulted
from the decreased use of tap water.
Use of the technology minimizes discharges of coloured wastewater
8.0 Obstacles, Problems and/or Known Constraints
Economic feasibility of the technology depends on the availability of activated carbon, and the lack of costs
associated with carbon regeneration in this case.
9.0 Date case study was performed: 1974 and 1976
10.0 Contacts and Citation
10.1 Type of Source Material: Conference Proceedings
10.2 Citation: A Study on Reuse of Water in a Woollen Mill. Hu Hiajue et al. Purdue Universty
Conference on Industrial Waste Treatment
10.3 Level of Detail of Source Material: Additional information is available in the source material
10.4 Industry/Program Contact and Address: Not provided
10.5 Abstractor and Address: Reformatted: Isaac Diwan, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Coloured wastewater
11.2 Process Type/Waste Source:
11.3 Waste Reduction Technique: Wastewater reuse
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Coloured Wastewater, Wastewater Reuse, Textiles
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***** DOCNO: 400-027-A-216 *****
1.0
2.0
3.0
4.0
5.0
6.0
Headline: Application of counter-current rinsing and washing in woollen industry.
SIC Code: 2299, Textile Goods, NEC, ISIC 3211 Textile, Clothing and Leather Industries
Name & Location of Company: Textile Industry in France
Clean Technology Category
This technology involves recycling, reuse and reclamation of wool wash water.
Case Study Summary
5.1 Process and Waste Information: Fleece (raw wool) contains about 40 % impurities by weight which
must be removed with the conventional technology. Fleece is beaten and then washed and rinsed
in water. Centrifugation of wash water permits recovery of suint and recycling of part of the wash
water to the washing baths. Mud and heavy grease separated by centrifuge are discharged to a
holding pond.
A number of modifications and new operations are introduced. These include the reuse of rinse
water rather than its discharge to public sewers. Effluent from the first washing bath is centrifuged
to recover suint and to recycle part of the washing water. Bottom residual water loaded with mud
and heavy grease is subjected to further treatments consisting of a multiple effect evaporation to
concentrate the grease. Water condensate is reused in rinsing and washing. Grease concentrate
is vacuum dried to produce a combustible residue (oil distillate and bitumen) for the evaporation
boiler. Liquid wastes are completely eliminated with the low waste technology.
No additional pollution control measures are required with the Low Wastage Technology, except
for the treatment of fumes from the boiler with a bag-filter.
5.2 Scale of Operation: Annual production capacity is 18,500 tonnes of wool per year (285 days of
operation per year).
5.3 State of Development: This technology is fully implemented
5.4 Level of Commercialization: Not reported
5.5 Balances arid Substitutions:
Material Category
Waste Generation:
SO2 emissions
Water Use:
Energy Use:
Economics*
Quantity
Before
N/A
7.5 mVtonne
0.6 GJ/tonne
1.5 kg/tonne wool
2 nrVtonne
5.2 GJ/tonne
6.1 Investment Costs: 15,000,000 French Francs (1981) compared to 32,500,000 FF for conventional
technology if a conventional effluent treatment is constructed
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6.2 Operational and Maintenance Costs: F 195/m wool washed
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits
Economic benefits are achieved while regulations are met. Aqueous wastes disappear completely with the
low pollution technique. Both techniques bring about atmospheric pollution of 0.5 kg of dust per ton. The
low pollution technique allows the reduction of the SO2 discharged from 2 kg to 1.5 kg per ton.
8.0 Obstacles, Problems and/or Known Constraints
Not reported.
9.0 Date case study was performed: 1981
10.0 Contacts and Citation
10.1 Type of Source Material: Organizational Report, "Counter-current Rinsing and Washing Including
^ Recycling of Rinsewater and Treatment of Washing Water from Wool Washing."
10.2 Citation: United Nations Economic and Social Council, Compendium on Low and Non-waste
Technology, ENVAVP.2/5/Add.27 Economic Commission for Europe, July, 1981.
10.3 Level of Detail of Source Material: Additional information available in the source.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: Reformatted: Isaac Diwan, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Wool (fleece) wash water
11.3 Waste Reduction Technique: Reuse, recycle
11.4 Other Keywords: Grease, vacuum dried, evaporation
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textiles, Wastewater, Wool, Counter-Current Rinsing, SIC 2299, ISIC 3211
2-354
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Cotton Production
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Minimized Environmental Effects in Cotton Production from Organic Growing to Garment
Reuse
2.0 SIC/ISIC Code: 0131, 0724, 22XX
3.0 Name and Location of Company:
Novotex A S, Denmark
4.0 Clean Technology Category: The methodology employed here is to produce cotton with the smallest
environmental impact by minimising emissions, energy conservation, and waste minimization. The
techniques employed involve all the stages from growing the cotton to recycling of unwanted garments.
The first stage is cotton growing, which the company is trying to insist that the growers perform
organically without artificial fertilizers, chemical pesticides, and defoliant sprays. Also, company policy
demands that all of the cotton used be handpicked to avoid defoliants and does not contain pesticide residue.
Vegetable compost and manure can supply the soil with necessary nitrogen and organic materials.
Cotton is spun on advanced computer controlled machines that require greater control of the otherwise
dusty atmosphere. Also, only water soluble dyes are used on the cotton and chloride for bleaching is
eliminated by using hydrogen peroxide. Dyeing is performed in fully enclosed high pressure jet machines
with reduced water consumption and no air pollution. In the drying process, mechanical finishing is
performed, eliminating the use of chemicals. Dust from the manufacturing of cotton garments is reduced
using dust extraction at the cutting and sewing machines. AH wastewater is treated, using chemical
precipitation with lime and iron salts to remove the dye and phosphorus, activated sludge biological
treatment occurring in 14 meter high towers, followed by sand filtration and aeration prior to discharge.
The company also tries to promote reusing garments, either for continued reuse by another person or for
conventional recycling for another use.
5.0 Case Study Summary:
5.1 Process and Waste Information: The facility applies environmental friendly measures on the stages
of spinning, knitting, dyeing, finishing, garment production, packaging and transport.
Simultaneously, the company carries out a Life Cycle Analysis of each stage of production to
examine the environmental aspects of every area of operation
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: Novotex A S is currently implementing the practices described herein.
5.4 Level of Commercialization: The practices described are readily available.
5.5 Material/Energy Balances and Substitutions: When the facility started operation, 1 percent of its
cotton was organically grown, this is now 10 percent and the facility expects it to continue to grow
as consumers around the world are enlightened. The facility has cut water usage in the dyeing
process by 50 percent and in the heated cleaning line by 67 percent. Also, the drying machines
recycle 75 percent of the hot air used and the wastewater discharge from the plant contains a small
fraction of the toxic material limits set by the water authority.
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6.0 Economics*
6.1 Investment Costs: Not Provided.
6.2 Operational and Maintenance Costs: Not Provided.
6.3 Payback Time: Not Provided.
7.0 Pollution Prevention Benefits
The organic growing method produces healthy plants without polluting the soil and the surrounding
environment. Also, the working environment has been improved at all stages of production and the
environmental impacts of each stage of production have been minimized.
8.0 Obstacles, Problems, and/or Known Constraints
None Described.
9.0 Date Case Study Was Performed: Not Provided.
10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Flain, Clean Technology Coordinator for DoE, "Minimised Environmental Effects in Cotton
Production," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available hi the source document.
10.4 Industry/Program Contact and Address: M Leif Norgaard, Managing Director, Novotex A S,
Ellehammervej 8, DK-7430, Ikast, Denmark, Tel: +45 97 15 44 11
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Chlorine bleach, Water insoluble cotton dyes
11.3 Waste Reduction Techniques: Organic growing, Handpicked cotton, Product substitution, Dust
Control
11,4 Other Keywords:
11.5 Country Code:
12.0 Assumptions
None.
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13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Chlorine bleach, Water insoluble cotton dyes, Organic growing, Handpicked cotton,
Product substitution, Dust Control
2-357
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Recovery and reuse of water in wet processing in a textile mill.
2.0 SIC Code: 2299, Textile Goods Manufacture
3.0 Name & Location of Company: Bombay Textile Research Association Member Textile Mill, Bombay,
India
4.0 Clean Technology Category
Technology Principle: The technology involves the recovery and reuse of wastewater in wet processing.
5.0 Case Study Summary
5.1 Process and Waste Information: In a BTRA member mill, a month-long study was carried out to
study the opportunities for conservation and reuse of water in its wet processing department. The
following measures were suggested:
Reduce the rate of flow of water and the throttling of water supply in washing machines.
Counter the current flow of washing on soapers, mercerizing machines, J-box range, etc.
Effectively reuse wash waters at some preceding point in the processing sequence, or by a common
sump and pump technique.
Collect and reuse steam condensate for boiler feed water.
Reuse steam condensate from caustic soda recovery plant in washing of mercerized goods.
Apply static washes on jiggers in place of overflow washes.
Use sodium bicarbonate in place of acetic acid for the oxidation of vat-dyed goods for easy removal
of caustic soda.
Recycle water for washing of blankets on printing machines.
Reduce the number of washings in a process sequence by giving appropriate treatments to fabric.
The bulk trails for such conservation and reuse measures were carried out in the mills during the
processing of a number of fabric varieties like bleached longcloth, dyed poplin, bleached
mulls/voiles, and dyed mulls and voiles.
5.2 Scale of Operation: Not reported
5.3 State of Development: Process suggestions fully implemented.
5.4 Level of Commercialization: Not reported
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5.5 Balances and Substitutions: Total fresh water consumption before the survey was 183,350
liters/day. After the survey, consumption was 11,950 liters/day. Net savings in fresh water
consumption per year was 21,720,000 liters.
Quantity
Before
183,350 liters/day
85,200 liters/day
Quantity
After
110,950 liters/day
157,550 liters/day
Material Category
Water Use:
Water Reused:
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Total fresh water consumption before survey was 183,350
liters/day. After survey, at was 11,950 liters/day. Total savings in water consumption per year
equals 21,720,000 liters. Monetary benefits amounted to 130,320 rupees per year.
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits: Savings from reduced water consumption amounted to 130,320 rupees per
year (taking cost of water at 60 rupees per 10,000 liters of water).
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date of Case Study: 1985
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings
10.2 Citation: "Seminar on Avenues for Cost Reduction in Chemical Processing of Textiles," held on
February 26, 1985 by Bombay Textile Research Association, Bombay 400 086, BTRA No. 06.3.1
10.3 Level of Detail of Source Material: Additional information is available from the source.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Work Group, Paris. Reformatted by: Marilu Hastings, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Wet processing, SIC 2299
11.3 Waste Reduction Technique: Wastewater recovery, reuse
11.4 Other Keywords: Annual cost savings
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wastewater, Wet Processing, SIC 2299, Wastewater Recovery, Reuse, Annual Cost Savings
2-359
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Conversion of willow dust into biogas at cotton textile processing mill.
2.0 SIC Code: 2211, Cotton Fabric Mill
3.0 Name & Location of Company: Apollo Textile Mills, Bombay .India.
4.0 Clean Technology Category
Technology Principle: The technology involves the conversion of willow dust into biogas and organic
fertilizer.
5.0 Case Study Summary
5.1 Process and Waste Information: Textile mills generate considerable quantities of solid waste
materials during different stages of operation. Willow dust is a waste generated from a willow
machine. In India, 30,000 to 33,000 tonnes of this material is generated every year. To convert
this willow dust into biogas, a pilot plant was installed at Apollo Textile Mills in Bombay with
assistance from the Cotton Textile Research Laboratory (CTRL). This plant has a 12.5 ton/month
capacity. 350 m3 of biogas was produced per 2 tons of willow dust for a retention period of 90
days.
The mill's average production of willow dust is 12.5 tons/month. The consumption of liquid
propane gas by the laboratory alone has been reduced by 65 kg since the installation of this
converter.
The scientists at the CTRL have further developed a process which needs less water, and double
the quantity of material can be accommodated in the same unit. Improvements have been made so
that the calorific value of biogas is increased. Also, the organic substance that is a by-product of
fermentation can serve as a good fertilizer.
5.2 Scale of Operation: Average monthly production of willow dust is 12.5 tons.
5.3 State of Development: The clean technology is fully implemented.
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions: Not reported
6.0 Economics:* It is assumed that the abbreviation "Rs." stands for "rupees." It is also assumed that the
word "lakhs" means "100,000 rupees."
6.1 Investment Costs: The investment cost of the project was 3.4 lakhs (lakh = 100,000 Rs.).
6.2 Operational and Maintenance Costs: Operating costs, including water and collection of willow dust
and alkali, are about 18,000 Rs.
6.3 Payback Time: Not reported
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7.0 Cleaner Production Benefits
Benefits including biogas and organic fertilizer generation are as follows:
8.0
9.0
Biogas
Fertilizer
12,000 m3/year
24 tons/year
63,412 Rs.
2.400 Rs.
Economic benefits will also include reduction in gas expenditures and waste disposal costs.
Obstacles, Problems and/or Known Constraints
No information provided.
Date the Case Study was Performed: 1985.
10.0 Contacts and Citation
10.1 Type of Source Material: Organizational report
10.2 Citation: "Production of Biogas from Willow Dust: A Solid Cellulosic Waste from Textile Mills."
Cotton Technological Research Laboratory (CTRL). Adenwala Road, Matunga, Bombay - 400 019,
India.
10.3 Level of Detail of Source Material: Additional information is available from this source.
10.4 Industry/Program Contact and Address: Industry contact not provided.
10.5 Abstractor and Address: UNEP Work Group, Paris. Reformatted by: Marilu Hastings, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Dust
11.2 Process Type/Waste Source: Cotton textile processing, .SIC 2211
11.3 Waste Reduction Technique: Conversion of willow dust into biogas and organic fertilizer
11.4 Other Keywords: Material segregation, reuse
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Dust, Cotton Textile Processing, SIC 2211, Conversion of Willow Dust into Biogas and Organic
Fertilizer, Material Segregation, Reuse
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Poly vinyl alcohol recycling in the process of "sizing" cotton fibers in the textile industry.
2.0 SIC Code: 2211, Cotton Broadwoven Fabric Mills
3.0 Name & Location of Company: Referred to as "Textile Industry," located in South Africa.
4.0 Clean Technology Category
Recycling, reuse and reclamation: This technology involves the use of a closed-loop recycling including
a ultra-filtration membrane process to capture poly vinyl alcohol (PVA).
5.0 Case Study Summary
5.1 Process and Waste Information: Poly vinyl alcohol (PVA), polyacrylates (PAA) and starch are
used in the textile industry for "sizing" cotton fibers; a process where applied chemicals confer
strength to the fiber and protect it during the weaving process. The PVA, PAA and starch are
removed from the cloth after weaving by washing it in hot water in a "desizing" operation resulting
in an aqueous effluent containing these chemicals.
A ultra-filtration process to reduce the amount of PVA and starch in the effluent followed by a
closed-loop recycling operation was tested for 16 months in a pilot plant. The ultra-filtration
membrane used in this process recovered PVA successfully. Starch is enzymatically solubilized
prior to desizing and, therefore, can not be recovered. The film forming characteristics of the PAA
during testing were impaired by the formation of a calcium-polyacrylate complex.
5.2 Scale of Operation: Not reported
5.3 State of Development: The process was tested for 16 months in a pilot plant.
5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1 Investment Costs: The capital cost for the ultra-filtration plant is $600,000.
6.2 Operational and Maintenance Costs: Operating costs for ultra-filtration plant was $61,000.
6.3 Payback Time: The payback period is 15 months.
7.0 Cleaner Production Benefits
Economic benefits were calculated in terms of raw material savings based on 4DE 6 meters/year cloth
production:
a) PVA sizing - $ 420,000/year
b) Enzymes - $ 100,000/year
c) Steam - $ 20,000/year
This resulted in a net savings of $ 485,000/year from reduced waste generation (900 tons/year) and raw
material purchasing needs.
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; 8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date Case Study Was Performed: 1982
10.0 Contacts and Citation
10.1 Type of Source Material: Journal
10.2 Citation: Buckley, C.A. 1982. The Performance of an Ultrafiltration Recycling of Textile
Desizing Effluents. Water Science and Technology 14:705-713.
10.3 Level of Detail of the Source material: Additional information is available from this source
document.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Reformatted: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
11.0 Keywords
11.1 Waste Type: Textile mills, poly vinyl alcohol (PVA), polyacrylates (PAA), starch, wastewater,
desizing effluent
11.2 Process Type/Waste Source: Textile mill products, SIC 2211, cotton broadwoven fabric mills,
desizing effluent
11.3 Waste Reduction Technique: Effluent recovery, PVA (poly vinyl alcohol) recovery, ultra-filtration
process
11.4 Other Keywords: Wastewater reduction, South Africa
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textile Mills, Poly Vinyl Alcohol (PVA), Polyacrylates (PAA), Starch, Wastewater, Desizing Effluent,
Textile Mill Products, SIC 2211, Cotton Broadwoven Fabric Mills, Effluent Recovery, PVA (Poly Vinyl Alcohol)
Recovery, Ultrafiltration Process, Wastewater Reduction, South Africa
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***** DOCNO: 400-026-A-215 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Wastewater reduced and soda recycled using rinse procedures and
evaporators.
Textile, Clothing and Leather Industries/ISIC 3211
Ministere de PEnvironment et due Cadre de Vie
Direction de la Prevention des Pollutions
14 Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
The company performs mercerizing followed by rinsing in running water
and allowing recycle of the soda after concentration. The actual
mercerizing operation is identical except that the mercerizer used is more
automated: the cotton is immersed in a soda bath containing a wetting
agent. The rinsing, instead of taking place in three baths of water (hot then
cold) that are discharged after use, takes place in a stream of running water.
The rinse water is progressively filled with soda until it is concentrated
enough to profitably employ an evaporator to further concentrate it. The
concentrated soda is then recycled for mercerizing, along with the wetting
agent it contains.
Not reported
Pollution consists of residual soda; for each ton of thread, 100 kg of soda
remaining for the low pollution technique, versus 360 kg, in 13 m3 as
opposed to 80 m3.
Water
(1977 Francs)
F 1,100,000
F 1,320/ton thread mercerized
Not reported
Not reported
Not reported
Not reported
Reduction of the rate of waste discharge by 67 m3 per ton of thread
mercerized.
Reduces the amount of wastewater produced.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Counter-current Rinsing and Recycling of
Soda in Rinsewater from Mercerizing," Monograph ENV/WP.2/5/Add.26.
Textiles, ISIC 3211, Mercerizing, Counter-Current Rinsing, Rinse.
Procedures
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0
2.0
3.0
6.0
Headline: Efficient recovery and reuse of caustic soda from mercerizing washwaters.
SIC Code: 2299, Textile Good Manufacturers
Name & Location of Company: Bombay Textile Research Association (BTRA) Member Mill, Bombay,
India
4.0 Clean Technology Category
Technology Principle: This technology involved the efficient recovery and reuse of caustic soda from
mercerizing wastewater.
5.0 Case Study Summary
5.1
Process and Waste Information: A plant floor study examined mercerizing machines and a caustic
soda recovery plant in a textile mill. It was observed that only 75% of the caustic soda from
washwaters was collected, compared to the normal 85 %. Also, the caustic soda recovery plant only
recovered 81 % of the soda, as opposed to the normal 90%.
The probable causes of the low collection and recovery rates were inefficient washing in the
mercerized material, poor squeeze and high quantities of caustic left on the fabric,
overflowing/leakage of dilute caustic soda solutions from the washing tank, and seepage from the
underground storage tanks. The probable causes of poor recovery were the improper filtration of
caustic soda solution prior to recovery, poor heat transfer coefficient in the recovery plant due to
scaling of the metallic tubes of the heat exchanger, lower vacuum obtained by the barometric
condenser, and the inefficient removal of non-condensate gases from the evaporation body.
Necessary corrective steps were taken yielding significant cost savings.
5.2 Scale of Operation: Not reported
5.3 State of Development: System was fully implemented.
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions:
Material Category
Feedstock Use:
Economics*
6.1 Investment Costs: Not reported
Quantity
sfore
1,190 kg/day
Quantity
After
775 kg/day
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6.2 Operational and Maintenance Costs:
Particulars
Mercerizing production/
day of fabric
Caustic soda input/day
Collection from washwaters
Reuse of dilute solutions
in bleaching
Caustic soda recoverable
Recovery of caustic soda
Total caustic soda consumed
in mercerizing (Total input less
recovery/reuse)
Before
Study (Teg)
10,000
3,500
2,630
310
2,320
2,000
After
Study (kg)
10,000
3,500
2,975
475
2,500
2,225
1,190
775
Saving of caustic soda/day = 415 kg
Savings per day = 2,282.50 rupees
Savings per year = 684,750 rupees
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits: Savings in caustic produced monetary benefits of 684,750 rupees per year
and improved the quality of the fabric.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date of Case Study: 1985
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings
' 10.2 Citation: "Seminar on avenues for Cost Reduction in Chemical Processing of Textiles", held on
February 26, 1985 by Bombay Textile Research Association, Bombay 400 086, BTRA No.06.3.1
10.3 Level of Detail of Source Material: Additional information is available.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Work Group, Paris. Reformatted by: Marilu Hastings, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
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11.0 Keywords
11.1 Waste Type: Caustic soda
11.2 Process Type/Waste Source: Mercerizing, SIC 2299
11.3 Waste Reduction Technique: Reuse, recovery
11.4 Other Keywords: Textiles
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Caustic Soda, Mercerizing, SIC 2299, Reuse, Recovery, Textiles
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***** DOCNO: 400-085-A-314*****
HEADLINE:
Batch degreasing of cloth with solvent and solvent recycling reduce wastes
generated.
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS: '
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Spinning, Weaving and Finishing Textiles/ISIC 3211
This case study presents the effects of automating the degreasing of cloth
in aqueous solution. Degreasing of cloth is achieved with detergent before
dying in an aqueous solution. This process generates large amounts of
waste. When using solvent to degrease cloth in a continuous mode, the
volume of waste is reduced because the solvent is recycled.
Solvent, cloth
The wastes generated by this process consist of solvent distillation/recovery
column bottoms, and solvent resulting from the drying process. Solvent
fumes are collected by an activated charcoal filter. Fats are incinerated.
Water
FF 660,000 per 1,035 tons of cloth (1976 figures).
FF 171.5 per ton of cloth (1976 figures).
Not Reported
FF 640,000 per 1,035 tons of cloth in capital cost FF 144.5 per ton of cloth
in O&M costs.
For one ton cloth, the low-pollution technique requires 14.5 kg of solvent
and 2.47 GJ of primary energy. The standard technique requires 14 m3 of
softened water, 29 kg of detergent and 5.85 GJ of primary energy. The
low-pollution technique rejects solvent from the drying process while tats
are separated when distilling used solvents. The standard technique rejects
45 m3 of used water loaded with fats and washing products (135 kg of
oxidizable matter, 2 kg of equitox) per one ton of cloth.
With the low-pollution technique, effective wastes are nearly non-existent.
Another advantage of the low-pollution technique is that it permits energy
recovery by burning fats. With the low-pollution technique the quantity of
operations (continuous degreasing) is reduced. Therefore, working
conditions are improved.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Batch Degreasing of Cloth with Solvent,"
Monograph ENV/WP.2/5/Add.85.
Textiles, Solvent Recovery, Water-Based Detergents, Degreasing,
Distillation, ISIC 3211
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1.0 Headline: Modified pressure kiers save energy in a textile mill in India.
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Shri Ranjitsinghji Mills, Solapur and several other mills in Solapur, India
4.0 Clean Technology Category
Technology principle: This technology involves equipment modifications that allow the use of higher
temperatures and chemical concentrations and reduce total time required for total kiering operation.
5.0 Case Study Summary
5.1 Process and Waste Information: The productivity of conventional pressure kiers was increased by
reducing the time required for total kiering operation. Conventional pressure kiers were modified
in a few mills so as to allow steaming of different types of fabrics, pre-saturated with appropriate
chemical for scouring or bleaching. The temperature and concentration of the treating solution were
increased within controlled limits to reduce the time of treatment. The concentration of chemical
on the fabric was increased and the fabric steamed in the fashion of the J. Box system. This is the
first instance of the use of conventional pressure kier boiling using the J.Box steaming process.
5.2 Scale of Operation: Daily production of 2 lots of 2000 kg each.
5.3 State of Development: This technology is fully implemented.
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions: Not reported
Economics*
6.1 Investment Costs: Cost of modification is Rs 30,000 (1985)
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Estimated at less than one month.
Cleaner Production Benefits
6.0
7.0
8.0
9.0
Savings in electrical and thermal energy, water and time required for processing without sacrificing the
product quality. A significant economic saving of Rs 50,000 per month was obtained.
Obstacles, Problems and/or Known Constraints
Not reported
Date case study was performed: 1985
10.0 Contacts and Citation
10.1 Type of Source Material: Conference Proceedings
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10.2 Citation:
(1) M.D. Dixit, Bombay Textile Research Association, Bombay, India. In 43rd All India Textile
Conference in Bombay, December, 1986.
(2) S.N. Bhide and S.D. Mahajan, B.R. Damani Research Center, Ranjitsinghji Mills, Solapur,
India.
10.3 Level of Detail of Source Material: Additional information available from source material.
10.4 Industry/Program Contact and Address:
(1) M.D. Dixit, Bombay Textile Research Association, Bombay, India.
(2) S.N. Bhide and S.D. Mahajan, B.R. Damani Research Center, Ranjitsinghji Mills, Solapur,
India.
10.S Abstractor and Address: Reformatted: Isaac Diwan, Science Applications International
Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Not reported
11.2 Process Type/Waste Source: Not reported
11.3 Waste Reduction Technique: Not reported
11.4 Other Keywords: Not reported
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Textiles, SIC 2299
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1.0
2.0
3.0
5.0
6.0
7.0
8.0
9.0
Headline: Change from peroxide bleaching to sodium hypochlorite bleaching reduces costs.
SIC Code: 2211, Cotton Fabric Mills
Name & Location of Company: Bombay Textile Research Association (BTRA) Member Textile Mill,
Bombay, India
4.0 Clean Technology Category
Technology Principle: This technology involves the substitution of sodium hypochlorite for hydrogen
peroxide in bleaching.
Case Study Summary
5.1 Process and Waste Information: A cotton textile mill in Bombay was using hydrogen peroxide
bleaching treatment for textiles, including for those materials that were going to be dyed in medium
and dark colors. The BTRA suggested that the mill change to a sodium hypochlorite beaching
system. For antichloring of the treated goods, the mill was advised to use only about a 0.3%
hydrogen peroxide solution in order to achieve better results. The new process allowed the mill
to use less chemicals and reduce pollution.
5.2 Scale of Operation: Not provided
5.3 State of Development: The system was fully implemented.
5.4 Level of Commercialization: Not provided
5.5 Balances and Substitutions:
Material Category
Hydrogen Peroxide
Sodium Hypochlorite
Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs: The mill's earlier practice of using peroxide bleaching cost
94,650 Rs./month. The new sodium hypochlorite system cost 24,930 Rs./month. The mill could
save 836,640 Rs./year. [Assume Rs. is abbreviation for "rupees.")
6.3 Payback Time: Not reported
Cleaner Production Benefits: Savings in overall chemical consumption, reduced pollution load, and
resulting monetary benefits.
Obstacles, Problems and/or Known Constraints: Not reported
Date of Case Study: 1985
Quantity
Before
1.5% solution
None
Quantity
After
0.3% solution
3g/l
2-371
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10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings
10.2 Citation: "Seminar on Avenues for Cost Reduction in Chemical Processing of Textiles", held on
February 26, 1985 by Bombay Textile Research Association, Bombay 400 086, BTRA No.06.3.1
10.3 Level of Detail of Source Material: No further information is available.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Work Group, Paris. Reformatted by: Marilu Hastings, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Bleach
11.2 Process Type/Waste Source: Bleaching, SIC 2211
11.3 Waste Reduction Technique: Process redesign, substitution
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Bleach, Bleaching, SIC 2211, Process Redesign, Substitution
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1.0 Headline: An all-aqueous method replaces use of solvents during pthalogen blue dyeing.
2.0 SIC Code: 2299, Textile Goods Manufacturer
3.0 Name & Location of Company: Bombay Textile Research Association Member Mill, Bombay, India
4.0 Clean Technology Category
Technology Principle: This technology involved the replacement of solvents from the pad bath formulation
with an all-aqueous method of pthalogen blue dyeing.
5.0 Case Study Summary
5.1 Process and Waste Information: In one of the member mills of the BTRA, pthalogen blue dyeing
was carried out by a solvent method using Ahurasol TRAP. It was suggested to the mill that it
begin using an all-aqueous method of pthalogen blue dyeing. Large scale trials using this method
were carried out. The new method's results were found to be comparable to the conventional
process. In fact, the new method produced better coverage by the incorporation of small quantities
of reactive dyes in the process.
5.2 Scale of Operation: This mill produced 100,000 meters/month of material in the pthalogen blue
shade.
5.3 State of Development: Not reported
5.4 Level of Commercialization: Not reported
5.5 Balances and Substitutions:
6.0
Quantity
Before
Quantity
After
Material Category
Feedstock Use:
Chlore Blue 3GX
Copper Complex
Ahurasol TRAP
Urea
Noigen HC 30
Reactofix Red H8B
Ahuralan 42
Sodium Bicarbonate
Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Savings per meter of fabric dyed is 0.156 rupees and total
annual savings of 187,200 rupees.
6.3 Payback Time: Not reported
6.818
13.636
15.679
15.679
0
0.5
0.1
1.136
6.818
13.636
0
12.272
6.818
0.5
0.1
1.136
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7.0 Cleaner Production Benefits: Savings per liter of pad bath formulation = 2.09 rupees. Savings per month
of same = 15,600 rupees. Annual savings = 187,200 rupees. Apart from direct economic benefits, there
was an improved coverage of dye by incorporation of small quantities of reactive dyes.
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date of Case Study: 1985
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings.
10.2 Citation: "Seminar on Avenues for Cost Reduction in Chemical Processing of Textiles," held on
February 26, 1985 by Bombay Textile Research Association, Bombay 400 086, BTRA No.06.3.1
10.3 Level of Detail of Source Material: Additional information is available from this source.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor and Address: UNEP Work Group, Paris. Reformatted by: Marilu Hastings, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste Type: Dye, solvent
11.2 Process Type/Waste Source: Textile dyeing, SIC 2299
11.3 Waste Reduction Technique: Material substitution
11.4 Other Keywords: Annual cost savings
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Dye, Solvent, Textile Dyeing, SIC 2299, Material Substitution
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General Textile
***** DOCNO: DOCUMENT NOT AVAILABLE *****
i.O Headline: Water reuse in a textile industry reduces wastewater and BOD waste generation.
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: Binny Textile Mills, Madras, India
4.0 Clean Technology Category: This case study focuses on reuse of wastewaters and water conservation.
5.0 Case Study Summary:
5.1 Process and Waste Information: Four areas within the facility are the major wastewater producers:
(1) process and treatment department; (2) captive power generation unit (coal fired thermal power
station); (3) sizing department; and (4) yarn dyeing and printing department. The following
changes were undertaken to conserve water and reduce wastewater generation.
Reuse of pressure filters backwash water. Suspended solids that can easily settle are the main
pollutants in pressure filter backwash water. By collecting the backwash water in a pond, with a
minimum hydraulic retention time of 12 hours, the supernatant freed from the suspended solids can
be reused for gardening purposes. Periodically, the retained suspended solids are removed from
the pond and disposed of a solid waste in a landfill site. The net effect is conservation of 20 cubic
meters/day of freshwater, which the facility used for gardening purposes.
Reuse of wastewater from the dyeing and finishing department - About 1,200 cubic meters/day of
fresh water, including the evaporation loss, was used for quenching hot ash from the boiler house
prior to its disposal. Laboratory experiments confirmed that it is feasible to reuse hard wastewater
from the dyeing department for ash quenching in lieu of fresh water. Due to adsorption of colors
and dyes on the ash particles, there is a approximately a 20% reduction in BOD content in the
reused dye department wastewater. Approximately 1,200 cubic meters per day of fresh water was
conserved, with a reduction of 552 kg BOD/day.
Reuse of wastewater from the sizing department - In order to avoid spontaneous combustion and
to reduce the fines loss, freshwater was used to wet coal in the yard. By collecting in a pond the
low volume, high organic strength wastewater from the sizing department, all of the wastewater
could be reused for coal wetting. Appropriate facilities must be available at die pond to avoid
septicity. Wastewaters from the sizing department were completely reused and 27 cubic meters per
day of fresh water were conserved.
5.2 Scale of Operation: Unknown.
5.3 Stage of Development: The technology was fully implemented.
5.4 Level of Commercialization: Not applicable
5.5 Material/Energy Balances and Substitutions: Not reported
6.0 Economics*
6.1 Investments Costs: Investment costs include the facility for pH neutralization pumps and pipeline
costs.
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6.2 Operational & Maintenance Costs: Savings and reduction in the capital investment is Rs. 7 lakhs
annually, and annual O&M costs are Rs. 6 lakhs. Annual savings for 300 workings days per year
for purchase of fresh water from the municipal corporation totalled Rs. 4 per cubic meter.
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits: Wastewater reused equals 2,690 cubic meters per day and freshwater
consumption was reduced 1.227 cubic meters per day. The overall reduction in wastewater quantity and
BOD load were 31 % and 25% respectively.
8.0 Obstacles, Problems, and/or Known Constraints: Not available
9.0 Date Case Study Was Performed: 1984
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished materials.
10.2 Citation: Mr. L. Paneerselvam, Director (PC), National Productivity Council, Lodhi Road, New
Delhi 110003, India.
10.3 Level of Detail of Source Material: Unknown
10.4 Industry/Program Contact and Address: Unknown
10.5 Abstractor Name and Address: The information in this case study was derived from abstracts
provided by the United Nations Environment Program (Paris). This abstract was prepared directly
from the abstract without access to the case study cited. Mary L. Wolfe, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile mill products, SIC 22
11.3 Waste Reduction Technique: Reuse
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wastewater, Textile Mill Products, SIC 22, Reuse-
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1.0 Headline: Nordic project on water use reduction in textile industries.
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: 15 textile facilities in Denmark, Finland, Norway, and Sweden.
4.0 Clean Technology Category
Process/Equipment Modification: This technology involves the introduction of automatic water stops to
encourage water conservation.
5.0 Case Study Summary: •
5.1 Process and Waste Information: Between 1976 and 1981, a Nordic "water care" project was
launched to examine avenues of water conservation in textile industries in Denmark, Finland,
Norway, and Sweden.
The following changes were reported for batch operations:
Winch dyeing: By dropping the dye batch and avoiding overflow rinsing, water consumption could
be reduced 25%.
High and Low Pressure Jet Dyeing: Approximately 50% of water consumption could be reduced
by replacing the overflow with batchwise rinsing.
Beam Dyeing: Avoiding overflow during soaking and rinsing can reduce water consumption by
approximately 60%.
Jig Dyeing: Switching to stepwise rinsing from the overflow practice resulted in water consumption
reductions of 15 %-79%.
Cheese Dyeing Apparatus: A water consumption reduction of 70% can be expected with the use
of an intermittent rinsing procedure.
For continuous operations, a savings of 20%-30% was reported by the introduction of automatic
water stops. Counter current washing was found to be most effective. Horizontal washing
equipment was found to deliver the performance of two vertical washing machines for the same
water consumption.
5.2 Scale of Operation: Initially, laboratory studies were carried out to ascertain potential possibilities.
Approximately 25 setups were installed at 15 textile plants.
5.3 Stage of Development: At the time the case study was reported, the technology was in the pilot
stage.
5.4 Level of Commercialization: It is unknown whether the technology was commercially available at
the time of the case study.
6.0
5.5 Material/Energy Balances and Substitutions: Not reported
Economics*:
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6.3 Payback Time: The only technology with a known payback tiine is beam dyeing, which has a
payback time of about four months.
7.0 Cleaner Production Benefits: Substantially reduced fresh water consumption and reduced cost of effluent
treatment plant.
8.0 Obstacles, Problems, and/or Known Constraints: None reported.
9.0 Date Case Study Was Performed: 1976
10.0 Contacts and Citation
10.1 Type of Source Material: Conference Proceedings
10.2 Citation: H. Asnes, "Reduction in Water Consumption in the Textile Industry," IFATCC
Conference, London, 1978.
10.3 Level of Detail of Source Material: Unknown
10.4 Industry/Program Contact and Address: Unknown
10.5 Abstractor Name and Address: The information in this case study was derived from abstracts
provided by the United Nations Environment Program (Paris). This abstract was prepared directly
from the abstract without access to the conference proceedings cited. Mary L. Wolfe, Science
Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia 22043.
11.0 , Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC 22
11.3 Waste Reduction Technique: Wastewater reduction, equipment modification
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and
other factors.
Keywords: Wastewater, Textile Mill Products, SIC 22, Wastewater Reduction, Equipment Modification
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1.0 Headline: Reduction of Sulfide in Effluent from Sulfur Black Dyeing Using Hydrol, a Maize Starch
Industry By-Product
2.0 SIC/ISIC Code: 22XX, Textile Mill Products
3.0 Name and Location of Company:
Century Textiles and Industries Limited, Bombay, India
4.0 Clean Technology Category: This technique uses a by-product of the maize starch industry, hydrol, to
reduce the sulfur dye to the affinity form for dyeing of fabric rather than the old method of using sodium
sulfide. Experiments revealed that 100 parts of sodium sulfide could be substituted by 65 parts of the
hydrol by-product and 25 parts of caustic soda. The dyeing produced a similar quality product to that
produced using the sodium sulfide reducing agent. The sulfide concentration in plant effluent has gone
from 30 ppm to less than 2 ppm.
5.0 Case Study Summary:
5.1 Process and Waste Information: Sulfur dyes are an important product, but they cause pollution
problems due to the traditional reducing agents used with them. Sulphur dyes are water insoluble
and must be converted into a water soluble (leuco) form before application to textile materials. The
traditional method is treatment with an aqueous solution of sodium sulfide. Since the leuco
compounds have an affinity for cellulosic fibers and are sensitive to atmospheric oxygen, they must
be applied from the aqueous solution. After the-dye has been absorbed on the fiber surface, the
reduced form of the dye must be reconverted into the water insoluable form. Generally, this is
carried out through exposure to air or by using a chemical oxidizing agent.
Black dye is an important member of the sulfur series due to its fastness in washing and light and
its low cost as compared to other synthetic dyes. It is converted using the process described above.
The facility encountered difficulties, however, when the State pollution control board established
a 2 ppm maximum sulfide content for treated effluent from textile mills. Rather than attempt to
reduce the sulfide in the effluent, the facility sought options to reduce or replace the sodium sulfide.
During studies conducted by the facility, it was discovered that an alkaline solution of glucose can
satisfactorily reduce the sulfur colors, enabling the facility to substitute the glucose solution for the
sodium sulfide. Because the glucose solution prepared in the studies would be cost prohibitive, the
facility sought an inexpensive source of glucose. This lead to the use of liquid glucose, a
by-product of the starch industry.
The traditional reducing method is treatment with an aqueous solution of highly polluting sodium
sulfide, causing an increase in the sulfide content of the plant's effluent. The new process
eliminates sulfide usage and thereby reduces effluent pollution. The facility replaced 100 parts
sodium sulfide (50%) with 61 parts liquid glucose (80% solids) and 26 parts caustic soda in its
sulfur black color dye operations. The facility continued to have difficulties with this mixture
because the thick glucose solution required special arrangements for emptying drums. The
operation was still cost intensive.
The facility finally substituted an alkaline solution from sugar reduction for the sodium sulfide. A
by-product containing 50% reducing sugars was technologically and financially feasible. The
facility substitutes 100 parts sodium sulfide (50%) with 65 parts of the product (containing 50%
. reducing sugars) plus 25 parts caustic soda. Dye qualities were equivalent to the standard process
for depth of shades, fastness, and other properties.
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6.0
5.2 Scale of Operation: This technique is operated at a plant of unknown capacity.
5.3 Stage of Development: This process is fully implemented in the production process.
5.4 Level of Commercialization: The substitute materials are commercially available.
5.5 Material/Energy Balances and Substitutions: Not Identified.
Economics*
6.1 Investment Costs: No investment costs were involved in this substitution. The substitute chemical
used was a waste stream from the maize starch industry, which saved Century Textiles about
US$12,000 in capital expenses. The savings in not having to install wastewater treatment was about
US$20,000 in capital expenses.
4.
6.2 Operational and Maintenance Costs: Operating costs were found to be marginally lower. The
saving in not having to install wastewater treatment was about US$3,000 in annual expenses. The
savings in using the substitute chemical is about US$1,800 per year in operating expenses. Also,
there has been a considerable but unquantified saving in money and convenience due to the
reduction in handling and storage.
6.3 Payback Time: Not Identified.
7.0 Pollution Prevention Benefits
The advantages of the cleaner production include a reduction of sulfide in the wastewater (meeting the
mandatory effluent level), improved settling characteristics in the secondary settling tank of the activated
sludge unit, less corrosion in the treatment plant due to reduced sulfide levels, and the elimination of foul-
smelling sulfide odors.
8.0 Obstacles, Problems, and/or Known Constraints
The substitution resulted in a slight increase in the biochemical oxygen demand (BOD) load, but the
increase was not found to be critical and was easily managed with the existing biological treatment system.
The high cost of glucose was the main constraint in making the technology have practical applications.
Further, the glucose solution required special handling when drums were emptied and solution replacement
was cost intensive. These problems were resolved by the use of suitable by-products containing reducing
sugars.
9.0 Date Case Study Was Performed: The process has been in use since April 1990.
10.0 Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "Reduction of Sulphide in Effluent from
Sulphur Black Dyeing," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
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10.4 Industry/Program Contact and Address: Mr R K Dalmia, Joint President (Works), Mr Mahesh
Sharma, Manager (Chemical Technology), Century Textiles and Industries Ltd, Worli Bombay,
India 400 025, Tel: +91 22 430 03 51
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
11.0 Keywords:
11.1 Waste Type: Wastewater
11.2 Process Type/Waste Source: Fabric Dyeing, Black Sulfur Dyeing
11.3 Waste Reduction Techniques: Material Substitution
11.4 Other Keywords: Sodium Sulfide, Reducing Agents
11.5 Country Code:
12.0 Assumptions
None.
13.0 Peer Review
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastewater, Fabric Dyeing, Black Sulfur Dyeing, Material Substitution, Sodium Sulfide, Reducing
Agents
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*****DOCNO: 400-086-A-315*****
HEADLINE:
INDUSTRY/SIC CODE:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CTTATION/PAGE:
KEYWORDS:
Computer process control reduces tank bottom losses, improves pigment
analysis, and reduces feedstock requirements as well as waste generation
rate in textiles industry.
Spinning, Weaving and Finishing Textiles/ISIC 3211
This audit presents the advantages of introducing process control in the
pigmentary printing of cloth. First the paste is prepared, then the cloth is
printed, dried, and the printing is polymerized. Differences between the
conventional and low-waste technologies are in the dressing of the paste.
Computer control which is used in the low-pollution process reduces tank
bottom losses, and improves the paste's analysis. The paste produced by
the low-pollution process contains less white spirit and more water.
For 1,000 m2 of cloth using low-pollution technique:
55 kg of white spirit
10 kg miscellaneous products
185m3 of water
Rejected washing water containing white spirit, white spirit fumes generated
during the drying stage, and reusable tank sediments.
Aqueous, air, solids
FF 3,730,000 (1980 figures) for an annual production of 2,300,000 m2 of
cloth.
FF 5.93 per 1,000 m2 of cloth (1980 figures)
FF 1.53 per 1,000 m2 of cloth
Difference between the conventional and low-pollution technique is 165 kg
of white spirit per 1,000 m2 of cloth.
Low-pollution technique generates the following quantities of wastes per
1,000 m2 of cloth: 7.5 kg of rejected washing water containing white spirit
(against 57 kg), 50 kg of white spirit fumes discharged at drying stage
(against 175 kg), and 28 kg of reuseable tank sediments (against 57 kg).
The additional consumption of energy results from the analysis of the paste
which contains more water and therefore takes longer to dry.
5.85 GJ for the low-pollution process against
4.60 GJ for the conventional process.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, 'Pigmentary Printing of Cloth with Paste
Containing Little White Spirit," Monograph ENV/WP.2/5/Add.86.
Textiles, Wastewater, Pigments, ISIC 3211
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Water and energy conservation through installation of recovery systems in textile industries of
Rajasthan, India.
2.0 SIC Code: 2200, Textile Mill Products
3.0 Name & Location of Company: Referred to as "Textile Mills" located in Rajasthan State, India
4.0 Clean Technology Category
Recycling, reuse and reclamation: This technology involves the installation of recovery systems to reduce
wastewater in three textile mills.
5.0 Case Study Summary
5.1 Process and Waste Information: (1) In the first plant, a 13,300 pound "Kier" on steam with no
water recovery was using approximately 700,000 gal water/day. A 5000 pound Kier was added
and a recovery system was activated into a new hot water system under pressure. The plant
restricted the water use by placing flow reducers into large lines. (2) In the second plant, 30-35
gallons of water were being used/pound of fabric dyed. Conservation measures of examining the
process and restricting water use reduced the water use to 30 gal/pound of fabric dyed. (3) In the
third plant, there was a reduction of approximately 800,000 gal/day of wastewaters by the addition
of a cooling tower for recirculation of water.
5.2 Scale of Operation: Not reported
5.3 State of Development: Not reported
5.4 Level of Commercialization: Not reported
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: -Not reported
7.0 Cleaner Production Benefits: Not reported
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date Case Study Was Performed: 1987
10.0 Contacts and Citation
10.1 Type of Source Material: Document
10.2 Citation: Document on Textile Processing Industries. Rajasthan State Board for Prevention and
Control of Water Pollution. Jaipur, India. September 1983.
10.3 Level of Detail of the Source material: Additional information is available from this source
document.
2-383
-------
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Reformatted: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
11.0 Keywords
11.1 Waste Type: Wastewater, rinse water
11.2 Process Type/Waste Source: Textile mill products, SIC 2200, textile mill production
11.3 Waste Reduction Technique: Process waste recovery
11.4 Other Keywords: Wastewater recovery
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wastewater, Rinsewater, Textile Mill Products, SIC 2200, Textile Mill Production, Process Waste
Recovery, Wastewater Recovery
2-384
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**** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Reclamation of sewage effluent for process use in textile industry.
2.0 SIC Code: 2200, Textile Mill Products
3.0 Name & Location of Company: Referred to as "Textile Industry," located in Bhutan
4.0 Clean Technology Category
Recycling, reuse and reclamation and material/product substitution: This technology involves reclaiming
sewage effluent for the use in textile mill production process.
5.0 Case Study Summary
5.1 Process and Waste Information: Recycled water from sewage effluent at a textile mill is used in
the entire mill production.
The research on this project was carried out in two stages; (1) feasibility studies through laboratory
and mill experiments and (2) with the conversion of the entire mill production to the use of recycled
water from sewage effluents.
5.2 Scale of Operation: Not reported
5.3 State of Development: Not reported
5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions: Not reported
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: Not reported
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits: Not reported
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date Case Study Was Performed: 1980
10.0 Contacts and Citation
10.1 Type of Source Material: Journal
10.2 Citation: American Dyestuff Reporter, No. 1, 1980
10.3 Level of Detail of the Source material: Additional information is available from this source
document.
10.4 Industry/Program Contact and Address: Not reported
2-385
-------
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Refonnated: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
11.0 Keywords
11.1 Waste Type: Wastewater, sewage water
11.2 Process Type/Waste Source: Textile mills, SIC 2200, sewage effluent water
11.3 Waste Reduction Technique: Sewage effluent reuse, sewage effluent recycling, wastewater
recovery
11.4 Other Keywords: Wastewater reduction, Bhutan, water conservation
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wastewater, Sewage Water, Textile Mills, SIC 2200, Sewage Effluent Water, Sewage Effluent Reuse,
Sewage Effluent Recycling, Wastewater Recovery, Wastewater Reduction, Bhutan, Water Conservation
2-386
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*****DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Water reuse in textile industries in Bombay, India.
2.0 SIC Code: 2200, Textile Mill Products
3.0 Name & Location of Company: Referred to as "Textile Mills Under Mill Owner's Association" located
in Bombay, India
4.0 Clean Technology Category
Recycle, reuse and reclamation: This technology involved the use of the installation of wastewater
recycling systems.
5.0 Case Study Summary
5.1 Process and Waste Information: An average water consumption estimate from 25 textile mills in
Bombay, India was around 120-280 liters/kg of cloth.
Remodelling sewer systems to separate reusable wastewaters and direct them to a separate sumps
of adequate size to balance inflows and outflows (approximately 10-15% of the volume of water
to be reused). The reusable water will then be pumped and distributed by pipes to the point of
direct water reuse.
5.2 Scale of Operation: Not reported
5.3 State of Development: Not reported
• 5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1-2 Investment Costs and Operational and Maintenance Costs: For one of the mills in the study,
detailed cost breakup (1970 costs in U.S. $) for various degrees of water reuse was provided as
follows:
6.3 Payback Time: Not reported
7.0 Cleaner Production Benefits: Not reported
8.0 Obstacles, Problems and/or Known Constraints: Not reported
9.0 Date Case Study Was Performed: 1969.
10.0 Contacts and Citation
10.1 Type of Source Material: Conference proceedings
10.2 Citation: Arceivala, S.J., Kapadia, J.R. and Wadekar, V.R. Economy and Reuse of Water in
Textile Mills. All India Textile Conference. 1969. pp. E-9 to E-17.
2-387
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10.3 Level of Detail of the Source material: Additional information is available from this source
document.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Reformatted: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
11.0 Keywords
11.1 Waste Type: Wastewater, Rinse water
11.2 Process Type/Waste Source: Textile mill products, SIC 2200, Textile mill production
11.3 Waste Reduction Technique: Process water recovery
11.4 Other Keywords: Wastewater recovery
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Wastewater, Rinsewater, Textile Mill Products, SIC 2200, Textile Mill Production, Process Water
Recovery, Wastewater Recovery
2-388
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Evaluation of three clean technologies for adoption in textile industries in Thailand.
2.0 SIC Code: (1) 7216, Dry Cleaning Plant Exc Rug; (2) 2269, Finishers of Textiles, NEC; (3) 2200, Textile
Mill Products
3.0 Name & Location of Company: Referred to as "Textile mills" located in Bangkok, Thailand
4.0 Clean Technology Category
b
(1) Process/equipment modification: This technology involves the use of a dry cleaning machine which
uses a refrigeration unit to cool the drying air to reduce the amount of solvent remaining at the end of the
drying period. (2) Process/equipment modification: This technology involves the use of transfer printing.
(3) Material/product substitution: This technology involves the use of hyperfiltration in textile mills.
5.0 Case Study Summary
5.1 Process and Waste Information:
-v
(1) In a conventional dry cleaning machine, an activated carbon filter is used at the end of the
drying period which evaporates the solvent (perchloroethylene) into the cleaning room air. A dry
cleaning machine developed by BOWE of West Germany was evaluated. The BOWE machine uses
a refrigeration unit to cool the drying air to the degree so that only a little amount of solvent
remains at the end of the drying period.
(2) Transfer printing reduces the consumption and loss of dye materials.
(3) This technology implements the use of hyperfiltration plants reducing the pollutional load of
chemicals.
5.2 Scale of Operation: Not reported
5.3 State of Development: Not reported
5.4 Level of Commercialization: Not reported
5.5 Material/Energy Balances and Substitutions: Not reported
6.0 Economics*
6.1 Investment Costs: Not reported
6.2 Operational and Maintenance Costs: (1) The operating cost of the BOWE machine was found to
be 4 Bants/load less than the conventional machine. The fixed costs of the BOWE machine was
found to be higher by 5.68 Bahts/load. Operational and maintenance costs for the other two
technologies is not provided. The economic calculations made for the BOWE dry cleaning machine
assumed a load of 12 kg., working time of 8.5 hours/day and a cycle time of 30 minutes.
6.3 Payback Time: Not reported
2-389
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7.0 Cleaner Production Benefits
Economic benefits: (1) The BOWE machine was found to be 1.58 Bahts/Ioad costlier than the conventional
dry cleaning machine, so no benefits. No details of economic benefits was provided for the two other
technologies.
Regulatory compliance: (1) The emission of perchloroethylene are expected to be lower in the BOWE
machine but no standards exist (as of 1985) in Thailand for perchloroethylene. No details of regulatory
compliance was provided for the two other technologies.
8.0 Obstacles, Problems and/or Known Constraints
(1) The BOWE machine was found to be technically beneficial but not economical. The number and size
of dry cleaning mills in Thailand are very small, lending little commercial opportunities.
(2) The transfer printing technology is restricted to certain types of synthetic fibers. The market share of
transfer printing machines is less than 5% of the Thai textile industry, hence the impact of this technology
on the Thai textile sector is expected to be low.
(3) While this option was considered to be economically attractive and relevant to the Thai textile industry,
in-house technology support, especially with the design of and implementation of hyperfiltration plants, was
considered weak and therefore wide spread acceptance of the technology is lacking. Also, the Thai
weavers are resistant to change and keep the size formulations secret.
9.0 Date Case Study Was Performed: 1985
10.0 Contacts and Citation
10.1 Type of Source Material: Report
10.2 Citation: Clean Technologies for the Paper and Pulp Industry, the Textile Industry, and the Metal
Coating and Finishing in Thailand. Report submitted by Thailand Development Research Institute
Foundation to United Nations Environment Program. 1986.
10.3 Level of Detail of the Source material: Additional information is available from this source
document.
10.4 Industry/Program Contact and Address: Not reported
10.5 Abstractor Name and Address: UNEP Workgroup, Paris. Reformatted: Elizabeth J. Mooney,
Science Applications International Corporation, 7600-A Leesburg Pike, Falls Church, Virginia
22043.
11.0 Keywords
11.1 Waste Type: Perchloroethylene, wastewater, textile dyes
11.2 Process Type/Waste Source: Dry cleaning machines, SIC 7216, SIC 2269, finishers of textiles,
NEC, SIC 2200, textile mill products, desizing effluent, dry clean air emissions
11.3 Waste Reduction Technique: Refrigeration of solvents, textile dye reduction, hyperfiltration process
11.4 Other Keywords: Wastewater reduction
2-390
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations, and other
factors.
Keywords: Perchloroethylene, Wastewater, Textile Dyes, Dry Cleaning Machines, SIC 7216, SIC 2269, Finishers
of Textiles, NEC, SIC 2200, Textile Mill Products, Desizing Effluent, Dry Clean Air Emissions, Refrigeration of
Solvents, Textile Dye Reduction, Hyperfiltration Process, Wastewater Reduction
2-391
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-------
TIMBER PRODUCTS
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-------
***** DOCNO: 400-037-A-226 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Closed-circuit recycling of water reduces discharges.
Wood industry, manufacturing of wood objects, including ftirniture/ISIC
3311
Ministere de I'Environnement et du Cadre de Vie
Direction de la Prevention des Pollutions
14, Boulevard du General Leclerc
92521 Neuilly-sur-Seine Cedex, France
In the low pollution technique, the water necessary for manufacturing
circulates in a closed circuit and the fluid used to transport the fibers is
itself the final effluent. Only a quantity of water exactly equal to the
amount that evaporates during manufacturing is introduced into the closed
circuit.
The pollution discharged comes from the washing of the roof and floor by
rainwater and losses of cooling water. There are 0.8 kg of oxidizable and
suspended matter per ton, against 110 kg in the standard technique.
Wastewater
Not reported
Aqueous
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
The low pollution technique is more efficient than a standard treatment
solution and permits a greater technical adaptability in manufacturing, given
the possibility of utilizing toxic products.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recycling of Water in the Manufacturing
of Wood Fiber Panels," Monograph ENV/WP.2/5/Add.37.
Wood Fiber, Closed-Loop Water Recycle, ISIC 3311
2-392
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-------
TRANSPORTATION
-------
-------
***** DOCNO: 450-003-A-379*****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
POLLUTION PREVENTION
OPTIONS SUMMARY:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION:
KEYWORDS:
Automotive chassis manufacturer uses ultrafiltration system to recover large
volumes of oily wastes and wastewaters.
Transportation Equipment/ISIC 32
Budd Automotive
Kitchener, Ontario
A manufacturer of automotive chassis, generates wastes that are heavy with
oil, grease and solids from industrial washers and die-washing equipment,
along with cutting fluids. An ultrafiltration (UF) system was purchased to
recover the oil used in the press shop. The system breaks the oil-water
emulsion so that a dilute oil solution can be recovered. The oil solution
recovered from the UF unit is about 30-40% oil. An acid can be added to
concentrate the solution to about 60-70% oil. Some of the recovered oil is
reused in the plant, and some is sent to a company for rerefining. The
remaining oil is mixed with lime to form a dried lime slurry which is
disposed of at a landfill.
Wastes high in oil, grease, and solids
Unrecovered oil, dried lime slurry
Liquid
$100,000
Not reported
Less than 24
The washing system, consisting of four or five 8,000-gallon tanks, are now
emptied and refilled with fresh water every 6-12 months instead of every
3-6 weeks.
Waste requirements are reduced.
Oily waste generation is reduced.
Large volumes of oily wastes and washwaters are now being recovered
instead of requiring disposal. The system greatly reduces oil raw material
costs, water, and disposal costs.
"Catalogue of Successful Hazardous Waste Reduction/Recycling Projects,"
Energy Pathways Inc. and Pollution Probe Foundation, prepared for
Industrial Programs Branch, Conservation & Protection Environment
Canada, March, 1987, page 94.
Automotive, Ultrafiltration, Oily Waste, Recovery, ISIC 32
2-393
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-------
fe^vw^^W •'•• • • -:'.•:-'*•- -. -- <* 'MISCELLANEOUS
-------
-------
***** DOCNO: 400-004-A-195 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Oil-fired heating systems retrofitted conserve energy and reduce emissions.
Oil-fired Furnaces/SIC 3433
Canadian Combustion Research Laboratory, Energy Research Laboratory,
CANMET, Department of Energy, Mines, and Resources, Ottawa, Ontario
/ Mr. R. Breaton
Retrofitting oil-fired heating systems with special air mixing tube, positive
damper control, fuel shut-off valve to improve energy efficiency and to
reduce emissions. The changes to a conventional oil-burning furnace are:
(1) Replace air mixing tube
(2) Install smaller nozzle
(3) Solenoid shut-off valve in fuel line
(4) Positive damper in stack
(5) Interlocking wiring
Benefits range from 15-20% fuel cost reduction.
Oil
Emissions of CO, particulates, and hydrocarbons
Not reported
(1979 'Canadian Dollars) .
$400
Not reported
36 to 84
Not reported
20%
9% reduction in SO, and NO,
Reduces fuel consumption and waste emissions
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Retrofitting Oil Fired Furnaces,"
Monograph ENV/WP.2/5/Add.4.
Residential Heating, Heating Oil, SIC 3433
2-394
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***** DOCNO: 400-007-A-198 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Waste heat distillation recovers heat from cooling waters.
Sea Water Desalination, Nuclear Power Generation/ISIC 4200
Nord-Aqua Oy, Vuorimiehenpuistikko 4D, 00140 Helsinki 14, Finland.
The company uses low temperature waste heat distillation as a means of
heat recovery. Nuclear power plant cooling water discharges may be used.
A water stream containing waste heat is partially evaporated in vacuum and
the vapor is condensed to fresh water in heat exchange with colder cooling
water. The vacuum is created by barometric columns and air is pumped out
of the vacuum by means of water flows. A temperature difference of 7
degrees Centigrade between the warm and cold water streams is an
economical minimum requirement for the process.
Not reported
No waste, no chemicals
Not reported
(1979 Dollars)
$1,842,000
$l,503/ton
Not reported
Not reported
Not reported
Not reported
None
Local thermal pollution of power plants can be reduced by using larger
cooling water flow rates. The risk of radioactive pollution of water is
reduced, if all cooling water of a nuclear power plant condenser is used for
waste heat desalination.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Nord-Aqua Low Temperature Waste Heat
Desalination", Monograph ENV/WP.2/5/Add.7.
Waste Heat, Desalination, Heat Recovery, Nuclear Power, ISIC 4200
2-395
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***** DOCNO: 400-090-A-257*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Energy savings and pollution reduction result from supplementing gas
supply with evaporated solvents.
Printing, Publishing and Allied Industries/ISIC 3420
The process demonstrates the savings achievable by an over-all review of
the energy consumed in the manufacturing of adhesive tapes. Modifications
involve a change from indirect steam heating to direct gas firing, improved
air circulation and web transport in the oven, and supplementing die gas
supply with incinerated evaporated solvents. Three ovens are used in the
process. Solvents from one are returned to the burner which supplies
drying energy for all three ovens. Two of the ovens incorporate heat
wheels to preheat make-air.
Natural gas (22 GJ/ton product)
Solvent vapors
Gaseous
421,000 British Pounds
Not reported
32
151,000 British Pounds
6.5 - 10.2 (23-35%) GJ energy/ton of product
360 ton/year solvent vapors
Since current technology consists of emitting the solvent to the atmosphere
or burning the solvent in the exhaust air, pollution and fuel requirements are
reduced. Energy savings are realized by a more efficient drying system
which uses direct gas firing rather than steam heated drying. Air circulation
is also improved in the ovens.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Energy Saving and Pollution Prevention In
Adhesive Tape Ovens Using Gas-fired Solvent Incinerators and Waste Heat
Recovery", Monograph ENV/WP.2/5/Add90. .
Paper, Energy Review, Solvent Recovery, ISIC 3420
2-3%
-------
***** DOCNO: 400-102-A-263 *****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Use of a side stream separator improves particulate collection efficiency and
reduces energy needs.
Electricity, Gas and Steam/ISIC 41
The process controls coal-fired boiler particulate emissions through the use
of side stream separator technology. This technology can provide a highly
cost-effective means of reducing particulate emissions below levels currently
obtainable with conventional high efficiency mechanical collectors. A
portion (side stream) of the combustion gas is drawn off at the point in
which the gas stream reverses through a bag filter. This system has
demonstrated an improvement in the over-all efficiency of emissions control
for 15 boilers by an average of 55 per cent. The particulate emissions
levels have been reduced from 0.29 Ib/MMBtu to 0.13 Ib/MMBtu. In
addition, the collection efficiency of finer particulates increased to
approximately 90 percent from 66 per cent. All of this was done at
substantially less cost than a conventional control system.
Gaseous and particulate emissions from coal-fired boilers.
Gaseous
$700,000
Not reported
Not reported
Not reported
Not reported
Not reported
The side-stream separator system utilizes 60 per cent less energy than
operation of a full bag filter. The compact design and size of the system
allows for retrofitting of existing installations without major modifications.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Side Stream Separator Control of
Particulate Missions", Monograph ENV/WP.2/5/Addl02.
Particulate Emissions, ISIC 41, Pollution Control, Coal-Fired, Boilers
2-397
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CASE STUDIES FOR THE REUSE AND RECYCLING OF POST-CONSUMER WASTES
-------
-------
*****DOCNO: 400-002-A-193 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
Recycling of mixed plastic wastes by plastification into granules for
extrasion or injection molding.
Recovery of Mixed Waste Plastics, Manufacture of Plastic Items -
Unclassified Elsewhere/ISIC 3560
Fabrique Nationale de Herstal, Industrial Equipment and Service Division,
B 4400 Herstal (Liege), Belgium
This company performs plastification of mixed plastics into granules for use
in traditional extrusion or injection molding. After collection of industrial
plastic waste or after an automatic unit extracts plastic from household
garbage, this process reduces mixed plastic waste to reusable plastic
granules. The process proposed by F.N. Herstal S.A. at present covers the
industrial recycling of mixed polymer fractions. The process is concerned
primarily with urban plastic waste from household garbage. However, it
is also concerned with industrial plastic waste which has not as yet been
evaluated. The essential feature of the F.N.-CRIF homogenization process
is the short time in the molten state, coupled with intense mixing on a
plastification disc. This process is available on a turnkey basis.
Mixed plastic waste primarily from urban household garbage.
None.
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Plastic
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Not reported
Reduces the disposed waste to none.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Recovery of Mixed Plastic Waste
Products," Monograph ENV/WP.2/5/Add.2.
Plastic, Mixed Plastic Waste Recovery, ISIC 3560, F.N.-CRIF Process
3-1
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***** DOCNO: 400-082-A-253*****
HEADLINE:
INDUSTRY/SIC CODE:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DISPOSAL & FEEDSTOCK:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Pyrolysis of used tires provides disposal alternative and generates energy.
Manufacture of Chemical Products, NEC/ISIC 3529
The Foster Wheeler pyrolysis technology is a process in which used,
shredded tires are heated in absence of air to produce a light fuel oil, solid
fuel, and high grade steel. Hot gases (600°C), containing no oxygen, are
passed through the bed of tires causing pyrolysis to occur. Oil in (he vapor
phase is condensed and collected in the quench column. Remaining gases
either fuel the process or are recycled through the reactor. Solid products
are continuously removed from the reactor.
3
Tires up to 1.75 meters. 32% steel content. 4.577 GJ/ton energy required
per ton.
Light oil, solid fuel, steel, carbonaceous char
Liquid and solid wastes
6.65 million Pounds Sterling
1.655 million Pounds Sterling in first year
Return on investment of up to 35% based on 10 year operational life.
Cost of landfill, incineration, or reclaiming of used tires.
Not reported
Presenting disposal alternative for approximately 65% of 3,000,000 metric
tons/year of used tires.
This technology addresses the problem of disposing of the 3,000,000 metric
tons/year of used tires estimated to be generated in the U.K. 20-25% are
retreaded, 15-20% have alternate end uses, while up to 65% present an
immediate disposal problem. The products of this pyrolysis process are
readily distributable energy sources for which markets exist. Possibility
exists to apply the technology to a variety of feeds ranging from plastics to
urban wastes.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Foster Wheeler Power Products Limited
Pyrolysis Technology for Energy from Used Tires", Monograph
ENV/WP.2/5/Add82.
Tires, Energy Recovery, Waste Recovery, Pyrolysis, SIC 3529
3-2
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***** DOCNO: 400-001-A-192 *****
HEADLINE:
INDUSTRY/SIC CODE:
NAME/CONTACT:
TECHNOLOGY DESCRIPTION:
FEEDSTOCKS:
WASTES:
MEDIUM:
COST:
CAPITAL COST:
OPERATION/MAINTENANCE:
MONTHS TO RECOVER:
SAVINGS:
DIRECT COST:
FEEDSTOCK REDUCTION:
WASTE PRODUCTION:
IMPACT:
CITATION/PAGE:
KEYWORDS:
Quarry waste and waste glass is used in mineral products.
Manufacture of Non-Metallic Molded Mineral Products Unclassified
Elsewfaere/ISIC 3699
Mineral Products, Ave. du Bois 31, 4920 Embourg, Belgium. National
Institute of Extractive Industries (UNIEX), rue du Chera Zoo, 400 Liege,
Belgium
This company crushes quarry waste or glass for recycling, produces pulp
by mixing polyester resin with the charge, and places the pulp in ambient
temperature molds. After vibration, the shaped elements are taken out of
the mold. Material and energy requirements per ton of product
manufactured include: 1) 850 kg of mineral charges, 2) 130 kg of polyester
resin, 3) 20 kg of various materials, 4) 3 GJ of energy. The resulting waste
is nil and is comprised of any dust and styrene emanations.
Quarry waste and recycling glass
None
Solid
$ 1,666,667
$ 432,000
Not reported
Not reported
Not reported
Not reported
Not reported
Waste dumped in the environment is reduced to none.
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Use of Quarry Wastes or Waste Glass",
Monograph ENV/WP.2/5/Add.l.
Waste Glass, Quarry Waste, ISIC 3699, Molded Products
3-3
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: De-inking Process for Waste Paper Using Air Flotation Cells
2.0 SIC/ISIC Code: 26XX
3.0 Name and Location of Company:
St Regis Paper Co Ltd, United Kingdom
4.0 Clean Technology Category: Initially, the waste paper is pulped to breakdown and detach the ink from
the paper. This pulping is conducted at a relatively low temperature with a low energy output. De-inking
is carried out using a flotation cell using air, caustic soda (pH control), soap (foaming agent), sodium
silicate and hydrogen peroxide (brighteners and cleaners). No chlorine bleach is used. Chemical usage
is low and as the technology is further refined, additional reductions are anticipated. Foam from the
process is removed and centrifuged to around 50 percent solids for landfill disposal. The de-inked stock
is diluted and screened to remove small solids and then sent to a drum thickener.
The secondary de-inking process follows dewatering and kneading of die pulp. The secondary process
relies on carry over, rather than the addition, of chemicals.
The de-inking process allows a wider range of available waste paper to be converted to high quality
printing paper. Water is recycled and reused, and eventually passes on to the wastewater treatment plant.
Quality reprise paper containing 80 percent recycled fibers is possible.
5.0 Case Study Summary:
5.1 Process and Waste Information: Use of waste paper for recycled paper has often been criticized
because of the poor quality of the reprise paper. In the technology described here, a two stage de-
inking process is used to remove ink and dirt from the waste paper prior to being processed into
a feedstock suitable to make new paper.
5.2 Scale of Operation: Not Provided.
5.3 Stage of Development: The process is fully implemented.
5.4 Level of Commercialization: The availability of the process is not discussed.
5.5 Material/Energy Balances and Substitutions: Not Discussed.
6.0 Economics*
6.1 Investment Costs: Not Provided.
6.2 Operational and Maintenance Costs: Not Provided.
6.3 Payback Time: Not Provided.
7.0 Pollution Prevention Benefits
The benefits of mis process include allowing the use of a wider range of printed waste paper, the amount of dirt
in the finished paper is reduced thereby improving quality and reducing the amount of reject paper,
3-4
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8.0
9.0
10.0
11.0
12.0
the brightness of the finished paper is improved without the use of chlorine bleach, the energy requirements
are low, the demands on effluent and waste disposal are minimal, and the plant is safe to operate giving
minimum risk to personnel and the environment.
Obstacles, Problems, and/or Known Constraints
None Identified.
Date Case Study Was Performed: The booklet, on which the de-inking process was implemented, was
produced in 1993.
Contacts and Citation:
10.1 Type of Source Material: Booklet Article.
10.2 Citation: Cleaner Production Worldwide, United Nations Environmental Programme, produced by
Robert Plain, Clean Technology Coordinator for DoE, "De-inking Process for Waste Paper," 1993.
10.3 Level of Detail of the Source Material: Very little detail on cost and waste information was
available in the source document.
10.4 Industry/Program Contact and Address: Mr Harry Cyprus, St Regis Paper Co Ltd, Silverton Mill,
Hele, Exeter, Devon, EX5 4PX, Tel: +44 392 881601
10.5 Abstractor Name and Address: Jack Faulk, Science Applications International Corporation, 7600A
Leesburg Pike, Falls Church, Virginia, 22043
Keywords:
11.1 Waste Type: Waste paper
11.2 Process Type/Waste Source: Paper de-inking
11.3 Waste Reduction Techniques: Process modification
11.4 Other Keywords:
11.5 Country Code:
Assumptions
None identified.
13.0 Peer Review: Mary Waldron, Science Applications International Corporation, 7600-A Leesburg Pike, Falls
Church, Virginia 22043
(*) - Disclaimer: Economic data will vary due to economic climate,-varying governmental regulations and other
factors.
Keywords: Waste paper, Paper de-inking, Process modification
3-5
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Enzymatic wastepaper modification
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Geneacor International Europe Ltd, SF-02460 Kantvik, Finland.
4.0 Cleaner Technology Category
Higher proportion of lower-quality waste paper can be used in papennaking. This possibility is particularly
timely given the current emphasis on higher recycling levels.
5.0 Case Study Summary
5.1 Process and Waste Information: In practical terms, enzymes, such as the commercial product
Liftase A 40 (a blend of celluloses and hemicellulases), are pumped into the stock chest ahead of
the headbox at an addition rate of 0.5-2*0 I/dry ton pulp. Indicative conditions are a reaction time
of 20-120 min when enzymes are added to stock at 2.0-4.0 % consistency having a temperature of
40-60°C and a pH value of 4.0-7.0.
While the mechanisms of the reactions are not known, it is thought that the enzymes improve
drainage by attacking and removing colloids in the pulp slurry.
Laboratory work has also achieved better drainage from nonwood fiber pulps.
5.2 Scale of Operation: Mill scale application.
5.3 Stage of Development: Fully implemented.
5:4- Level of Commercialization: The equipment and enzyme needed are commercially available.
5.5 Material/Energy Balances and Substitutions:
OTY Before OTY After
positive effect*
6.0
• positive effect*
positive effect*
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
* The actual situation varies strongly case by case.
Economics*
6.1 Investment Costs: Nearly zero.
6.2 Operational and Maintenance Costs: Maintenance cost is nearly zero. Operational cost depends on
the amount of Liftase A 40 needed to get desired effect
3-6
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6.3 Payback Time: Short, but varies strongly case by case.
7.0 Cleaner Production Benefits
The basic effect of Liftase A40 treatment is improved drainage. This means for example possibilities to
use higher levels of low-quality waste paper because there is more room for using mechanical action
(refining) and/or headbox dilution for improving paper properties.
8.0 Obstacles, Problems and/or Known Constraints
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Journal articles.
10.2 Citation: (1) Grant, R., Biotechnology's potential is growing, PPI, May 1990, pp. 118-119;
(2) Grant, R., First mill-scale trials get underway, PPI, June 1991, pp. 61-63; (3) Pommier, J-C.,
Fuentes, J-L. and Goma, G., Using enzymes to improve the process and the product quality in the
recycled paper industry, Tappi Journal, June 1989, pp. 187-191; (4) Pommier, J-C., Goma, G.,
Fuentes, J-L. and Rousset, C., Using enzymes to improve the process and the product quality in
the recycled paper industry, Part 2: Industrial applications, Tappi Journal, December 1990, pp. 197-
202
10.3 Level of Detail of the Source Material: Additional information is available on request.
10.4 Industry/Program Contact and Address: Olli Jokinen, Product Manager, Pulp & Paper Enzymes,
Genencor International, SF-02460 Kantvik, Finland, phone: +358 0 297 4660, fax: +358 0 298
2203, telex: 121076 supo sf
10.5 Abstractor Name and Address: Olli Jokinen, Product Manager, Pulp & Paper Enzymes, Genencor
International, SF-O2460 Kantvik, Finland, phone: +358 0 297 4660, fex: +358 0 298 2203, telex:
121076 supo sf
11.0 Keywords
11.1 Waste type: Wastepaper
11.2 Process type/waste source: Paper production
11.3 Cleaner Production Technique: Enzymatic wastepaper upgrading
11.4 Other Keywords: Liftase A40, Drainage
11.5 Country Code: Finland.
12.0 Assumptions
13.0 Peer Review
Yes.
3-7
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Wastepaper, Paper production, Enzymatic wastepaper upgrading, Liftase A40, Drainage
3-8
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: The PAN TERRE plant
Recycled mixed paper panels are produced in the Pan Terre plant. The panels are 100 percent organic
products made of equal parts of mixed post-consumer paper and a vegetable fiber.
2.0 SIC/ISIC Code: 13419
3.0 Name and Location of Company:
Pan Terre, Belgium.
4.0 Cleaner Technology Category
The public pressure for increased paper recycling continues to rise. With growing concern over the
greenhouse effect and deforestation worldwide, every effort to leave trees uncut and instead reuse
wastepaper is an excellent investment for the global future.
The paper panels show many benefits - energy savings, environmental clean-up, reduced pressure on scarce
fuel and forest reserves, and a sounder economic footing for industry by reducing its dependence on costly
virgin resources imported from afar.
5.0 Case Study Summary
5.1 Process and Waste Information: Pan Terre panels are 100 percent organic products made of
roughly equal parts of mixed post-consumer paper and a vegetable fiber. Though wheat straw is
used in Belgium, rice husks, peanut shells, coffee bean hulls, bagasse and other similar materials,
preferably ones that are locally available, may be used as substitutes. Paper mill sludge also
performed well in this application, and offers the potential to manufacture heavier, stronger boards.
The typical recipe for the paper fraction is 80 % newspaper, 10 % magazines and 10 % corrugated
and boxboard grades.
Depending on intended end-use applications, other Pan Terre ingredients include an organic fire
retardant, 100 percent recycled cardboard surface-coats on some product lines, and an organic glue
for surface-coating.
The loose paper and straw drawn from the silo are weighed and manually batch-fed into a two-stage
hydropulping system, where the paper fibers break down and blend with the straw into a paste.
The material is not deinked, and process water is continuously treated so that there is no effluent
discharge.
The liquid paste, containing a high proportion of water, is conveyed to the preformer; at this stage
tramp metals are captured by a filter. The preformer operates like a hydraulic press. The preformer
achieves a uniform panel thickness and squeezes out about 30 % of the water without compressing
the fibers, thereby preserving the acoustical and heat-insulating properties of the panels.
From the preformer the pulp slabs are fed to the drying oven. The boards are dried by hot air
blown on both surfaces for even drying. The only water loss in the process occurs here through
evaporation. Using a heat exchanger, this steam is captured to heat the plant in winter.
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Boards intended for surface-coating continue to a sanding machine for the surfaces to be smoothed;
dust from this step is recycled to the hydropulper.
The panels continue to the finishing station, where they are surface coated, pressed and trimmed.
The trimmings are captured and returned to the pulper.
Pan Terre is unique for its acoustical and thermal insulating properties. As an acoustical material,it
has consistently performed above European standards for sound abatement. Pan terre has twice the
thermal insulating action of rock wool.
5.2 Scale of Operation: The Belgian plant consists of one line rated to consume 2,850 metric tons per
year of mixed waste paper and 3,400 metric tons of wheat straw. The plant produced about 100,000
panels in its first year, operating at 60 % of production capacity.
Plant designs for the U.S. will be of at least two production lines at this size. Larger installations
are also available.
5.3 Stage of Development: The Pan Terre process is fully implemented.
5.4 Level of Commercialization: The Pan Terre technology has first been realized as a pilot project
in Belgium in 1986. The Belgian industrial scale facility completed its first full operation year in
1989. Now the technology is available at industrial scale for licensing in the U.S.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
QTY Before
N/A
2,8501 waste
paper/y
N/A
N/A
QTY After
no waste
3,400 t wheat
straw/y
N/A
188 MJ
nat.gas/pound
6.0 Economics*
6.1 Investment Costs:
6.2 Operational and Maintenance Costs:
6.3 Payback Time:
7.0 Cleaner Production Benefits
The Pan Terre process is best described as intermediate or appropriate technology. The process hinges on
a natural reaction in the mixture of pulped paper and vegetable fibers, causing them to bind together
without the need of glue. Also, Terre developers resolved to design the technology so that it would yield
an all-natural product, and produce no process waste or pollution. They created a panel free of asbestos,
formaldehyde, blowing agents like chlorofluorocarbons, synthetic adhesives, urea, and other chemicals or
ingredients that could affect the environment or people. The production system avoids deinking and
3-10
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resulting effluents, and reuses all process water and scrap materials. The panels themselves are 100 %
recyclable.
8.0 Obstacles, Problems and/or Known Constraints
Certain contaminants, for instance self-sticking labels, poly-coated or plastic-coated paper, as in frozen food
packages or milk cartons, and treated facsimile and carbon papers should be held to a minimum. During
pulping, these materials can interfere with binding of the fibers, and in kiln drying, plastics will melt.
Also, removal of metal staples and paper clips is desirable to improve board dimensions and avoid sparks
during sanding.
9.0 Date Case Study Was Performed: The research work began in 1981. In 1983, Terre designed and
implemented a pilot scale production plant. In 1986 Terre was awarded a grant toward the costs of scaling
up the pilot plant to industrial level production. The new facility completed its first full operation year in
1989.
10.0 Contacts and Citation
10.1 Type of Source Material: Journal article.
10.2 Citation: Brewer, G., Quiet, cozy and green: recycled mixed paper panels, Resource Recycling,
January 1991, pp. 62-69
10.3 Level of Detail of the Source Material: More information on process background and product
properties as well as applications is available in the source material.
10.4 Industry/Program Contact and Address: Mrs Virve Tulenheimo, MSc, Research Engineer,
Technical Research Centre of Finland, Non-Waste Technology Research Unit, P.O.Box 205,
SF-02151 Espoo, Finland, Telephone +358 0 4561, Telefax +358 0 460 493, Telex 122972 vttha
sf
10.5 Abstractor Name and Address: Same as in 10.4.
11.0 Keywords
11.1 Waste type: Waste paper
11.2 Process type/waste source: Paper mill
11.3 Cleaner Production Technique: Recycled paper panels
11.4 Other Keywords: Insulating panels, Acoustic panels
11.5 Country Code: Belgium, USA.
12.0 Assumptions
13.0 Peer Review
Yes.
3-11
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(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Waste paper, Paper mill, Recycled paper panels, Insulating panels, Acoustic panels
3-12
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***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Recycling cement sack papers
Recycling cement sack papers into products with higher aggregate value. Desaggregation and cleaning
cement sack paper in water and bleaching it with peroxide.
2.0 SIC/ISIC Code: 13411
3.0 Name and Location of Company:
Instituto de Pesquisas Tecbnologicas do Estado de Sao Paulo S. A. - IPT, DPFTC - Agrupamento Celulose
e Papel, P.O.Box 7141,01064-970-SaoPaulo SP-Brasil, phone: 55 112682211, fax: 55 11 8693353, telex:
11 83144 INPT BR.
4.0 Cleaner Technology Category
Recycling papers into products with higher added value, such as sanitary paper.
5.0 Case Study Summary
5.1 Process and Waste Information:
Process Area: Paper recycling.
Base Process: Used cement sacks are torn into small pieces and fed into, a hydropulper for
disintegration and separation of dirt. The pulp formed with the desaggregated paper passes through
a vibratory or a pressurized screw.
The screened fibres, with a consistency of 10-12 %, are fed into a screw where they are mixed with
part of the chemicals (NaOH, EDTA, sodium silicate), going then to an other screw, where a
charge of hydrogen peroxide is applied.
It is necessary to perform some laboratory scale trials to determinate the appropriate charge of
chemicals that should be applied to the specific cement sack paper fibres. The brightness level
obtained depends on the conditions and the charge of chemicals applied to the fibres.
Depending on the kind of furnish used in the manufacture of the sack papers, it is possible that after
cleaning, the suspension of fibres shows coloured fibres. This kind of dirt can only be separated
from others with more complex and expensive methods of pulp cleaning, such as flotation and
deinking. These methods should be used because it is practically impossible to discolour such kind
of fibres by using peroxide only.
New Waste Stream: This method allows to recycle cement sack papers, but forms a slurry resulting
of the residual cement washed from the paper.
Raw Materials: Used cement sack papers, without any plastic coating or paint.
Energy Usage: Not yet computed.
Process Changes: The use of peroxide is suggested instead of chlorine in the stage of pulp
bleaching.
3-13
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Operating Procedures: The main operating procedure, described above is commonly used in the
industry of paper recycling. The only difference is that the furnish usually consists of cement sack
papers. These papers generally use fibres with a high content of residual lignin. This makes it
necessary to perform laboratory trials to adjust the condition of the peroxide bleaching.
5.2 Scale of Operation: A full-scale recycling mill has an annual output of 30-50 ADMT/day.
5.3 Stage of Development: Partly bench and partly pilot scale.
5.4 Level of Commercialization: The fundamentals of the technology are ready for use; some
adjustment is necessary for commercialization.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
Feedstock Use:
Water Use:
Energy Use:
OTY Before
N/A
N/A
N/A
N/A
OTY After
N/A
N/A
N/A
N/A
6.0 Economies'"
6.1 Investment Costs: Detailed economic figures have not been prepared, but the necessary equipment
is the same used in the regular mills for recycling papers.
6.2 Operational and Maintenance Costs: Depend on the case and situation.
6.3 Payback Time: Not available.
7.0 Cleaner Production Benefits
This alternative process allows to use recycled cement sack paper bleached pulp in the production of papers
of good quality.
8.0 Obstacles, Problems and/or Known Constraints
The technical constraints appear mainly if the furnish presents coloured fibres or plastic cover; or if the
price of chemicals is too high.
9.0 Date Case Study Was Performed:
10.0 Contacts and Citation
10.1 Type of Source Material: Personal contact, unpublished material.
10.2 Citation: Training report of Heli A. Sorsa for J.M. Neves: Bleaching with peroxide of secondary
fibres of cement sacks. IPT Internal Report, 1989.
10.3 Level of Detail of the Source Material: Fairly well detailed.
3-14
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10.4 Industry/Program Contact and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas
Technologicas do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel,
P.O.Box 7141, 01064-970-Sao Paulo SP-Brasili phone: 55 11 2682211, fax: 55 11 8693353, telex:
11 83144 INPTBR.
10.5 Abstractor Name and Address: Dr. Jose Mangolini Neves, Institute de Pesquisas Technologicas
do Estado de Sao Paulo S.A. - IPT, DPFTC - Agrupamento Celulose e Papel, P.O.Box 7141,
01064-970-Sao Paulo SP-Brasil, phone: 55 11 2682211, fax: 55 11 8693353, telex: 11 83144INPT
BR.
11.0 Keywords
11.1 Waste type: Slurry of residual used cement
11.2 Process type/waste source: Recycling of paper/cement sack paper
11.3 Cleaner Production Technique: Alternative recycling of cement sack papers
11.4 Other Keywords: Sanitary papers
11.5 Country Code: Brasil.
12.0 Assumptions
13.0 Peer Review
No.
(*) - Disclaimer: Economic data will vary due to economic climate, varying governmental regulations and other
factors.
Keywords: Slurry of residual used cement, Recycling of paper/cement sack paper, Alternative recycling of cement
sack papers, Sanitary papers
3-15
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B\DIV834\570F\IPPC\APPENDK.A
APPENDIX A
THE INTERNATIONAL CLEANER PRODUCTION CLEARINGHOUSE AND
THE POLLUTION PREVENTION INFORMATION CLEARINGHOUSE
-------
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The International Cleaner Production Information
Clearinghouse and The Pollution Prevention
Information Clearinghouse
The International Cleaner Production Information
Clearinghouse (ICPIC) and the Pollution Prevention
Information Clearinghouse (PPIC) are dedictated to
reducing or eliminating industrial pollutants through
technology transfer, education, and public awareness.
The Clearinghouses contain technical, policy,
programmatic, legislative, and financial information
concerning source reduction and recycling efforts in
the United States and abroad. They are free,
nonregulatory services of the UNEP-1E/PAC and the
U.S. EPA and are accessible by personal computer,
telephone hotline, or mail.
TJNEP-IE/PAC
Cleaner Production
Programme
The Cleaner Production Programme was established by the United Nations
Environment Progiamme(UNEP) Industry and Environment Programme
Activity Centre (ffi/PAC) in response to a decision from the UNEP Governing
Council on the need to reduce global industrial pollution and waste. The
Programme, which encompasses five elements (publications, training, working
group, technical assistance services, and ICPIC), was established with four
objectives:
}
• To increase worldwide awareness of the cleaner production concept
• To help governments and industry develop cleaner production programs
« To foster the adoption of cleaner production technologies
• To facilitate the transfer of cleaner production technologies.
To meet these objectives, the Programme focuses on the collection and
dissemination of information on industrial operations conducted using concepts and
technologies that prevent or reduce the generation of pollutants and wastes.
A-l
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ICPIC
ICPIC is a computerized information exchange system developed through a
cooperative agreement between UNEP and the United States Environmental
Protection Agency (U.S. EPA) to provide information to the international
community. It is patterned after its sister system, the U.S. EPA's Pollution
Prevention Information Exchange System (PIES) with which nightly file and
message exchanges occur. Both systems contain information that explains and
illustrates production using techniques that conserve raw materials and energy, that
eliminate the use of toxic raw materials, and that reduce the quantity and toxicity
of emissions and wastes from manufacturing operations.
Specifically, ICPIC contains:
• A Message Centre allowing communication with other users on all subjects,
including questions and answers to technical questions
• Bulletins containing the latest news and announcements in the international clean
technology community
• An On-line Repository affording electronic orders of hardcopy documents
• A Calendar of Events listing upcoming national and international conferences,
training seminars, and workshops
• A Case Study Data Base of technical and programmatic case studies
highlighting various industries, the wastes involved, economic incentives, and
cost recovery time periods
• An On-line Bibliography with hundreds of clean technology document abstracts
and information for ordering
• A Directory of Contacts representing an automated version of UNEP's Cleaner
Production Directory providing a list of the names, affiliations, addresses and
phone numbers of international technical experts and government
representatives.
• Access to PIES and to the U.S. EPA's Pollution Prevention Information
Clearinghouse (PPIC) through a topical conference system. Operating just like
the main system, the PIES conference includes a message center, bulletins, and
the data bases contained in the PIES as well as access to the other avenues of
information exchanges available through the PPIC
ICPIC has representation from over 40 countries. It contains 1,151 cleaner
production abstracts and 652 industrial case studies for an extensive list of different
industries. It also affords access to 160 cleaner technology professionals through
its directory of contacts.
A-2
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Accessing
ICPIC
PSN
Regular
Phone
line
Hotline
or Mail
Additional
Information
The ICPIC computer system can be accessed 24 hours a day by using a
personal computer or a dumb terminal equipped with a modem (1200 or 2400
baud) and appropriate communications software. With these equipment, the o
computer system may be contacted in one of three ways: (1) by direct dialing of
the system through a public telephone system, (2) by using the data Packet
Switching Network (PSN), "SprintNet," which is connected directly to ICPIC, or
(3) by using any other PSN that can access SprintNet. If you are calling from
outside France, SprintNet may be the least costly way to access ICPIC. For more
information or to find out the number of the PSN in your area, contact:
SprintNet
Mr. Paul Henric
Sprint International France S.A.
Mini-Pare du Verger
1, rue Terre Neuve
91967 Les Ulis Cedex B.
France
Tel: 33-1-64-46-23-24
Fax: 33-1-64-46-45-38
U.S. SprintNet:
Mr. Art MacDowell (commercial)
Data Division
U.S. Sprint
8229 Boone Boulevard
Suite 500A
Vienna, Virginia 22182
United States
Tel: 19-l-703-827-7238(direct)
19-1-703-827-0221
Fax: 19-1-703-827-7251
To access the system by dialing directly or via a PSN, set the communications
software to 8 data bits, no parity, and 1 stop bit, then dial either the ICPIC
telephone number (33-1-45-79-40-59), the SprintNet access number, or the
appropriate PSN access number. Once in ICPIC, all functions are easily performed
using abbreviated commands (e.g., E to look at a Bulletin, R to Read a message,
etc.).
Information in ICPIC can also be accessed by those without a computer,
modem or the appropriate communications software by contacting UNEP at the
address and telephone number provided below.
A users guide for ICPIC is available by contacting UNEP at the address
listed below. Information, questions and comments on ICPIC should be directed
to:
United Nations Environment Programme
Industry and Environment Programme Activity Center
Tour Mirabeau
39-43 quai Andre' Citroen
75739 Paris CEDEX 15
France
Telephone: 33-1-44-37-14-50
Facsimile: 33-1-44-37-14-74
Telex: 204 997F
Cable: UNITERRA PARIS
A-3
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PPIC
The U.S. EPA's PPIC is a national and international communications network
targetting multi-media source reduction and recycling opportunities and affording
information exchange through four means:
• Repository representing a hard copy reference library containing the most
current pollution prevention information including case studies, fact sheets,
programmatic and legislative information, and training materials
• The Pollution Prevention Information Exchange System (PIES), a 24-hour
electronic network consisting of message centers, technical data bases, issue-
specific "mini-exchanges" (including ICPIQ, and a calendar of events devoted
exclusively to pollution prevention
• .Hotlines providing toll-free telephone services to answer or direct questions and
to-link users without access to computer equipment to PIES
• Outreach Efforts including workshops and information packets containing
industry-specific materials on pollution prevention opportunities.
Accessing Regular Users with a personal computer or a dumb terminal equipped with a modem
PPIC Phone and the appropriate communications software may access PPIC by setting
Line • the communications software to 8 data bits, no parity, 1 stop bit and by calling
(703) 506-1025. A toll-free number has been established for authorized Federal,
State, and local government users. Such users should contact the PPIC Technical
Support Hotline (listed below) to see if they qualify for use of this number.
Hotline Individuals without access to computer equipment may obtain information from
PIES and PPIC by contacting the hotline and technical support numbers provided
below:
RCRA/Superrund Hotline:
Small Business Ombudsman (SBO) Hotline:
EPA Clearinghouse Hotline:
EPA PIES Project Manager
PIES Technical Support Hotline:
ICPIC Technical Support Hotline:
(800) 424-9346
(800) 368-5888
(202) 260-1023
(202) 260-3161
(703) 821-4800
(33) 1-45-79-40-59
A-4
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Mail Information may also be obtained by mailing a request to the following address:
Pollution Prevention Information Clearinghouse
U.S. Environmental Protection Agency (PM-211A)
401 M Street, SW
Washington, DC 20460
Telenet Telenet is a private data network service. If you already subscribe to this service,
dial your local Telenet access number. At the @ prompt, type: c 20256131 to
access the PIES. If you would like to receive information about how to subscribe
to Telenet, contact the PPIC. Note: Telenet is not affiliated with the U.S. EPA or
the PPIC.
Other If you have access to one of me U.S. private data services that has a gateway
17.5. to Telenet, you can connect to the PIES. These data systems are: BinNet,
Data Western Union, SNET, Bell Atlantic, Bell South, Ameritech, NYNEX,
Services Pacific Bell, Southwestern Bell, U.S. West, and Cincinnati Bell. Follow the local
access procedures established by your data network to connect to anouther network.
At their prompt, type: 311020256131 to access the PIES.
Overseas If you are a user outside North America, you must access a data service in
Data your country that has a gateway to Telenet (contact the PPIC for a complete
Service list of participating networks). Follow the local access procedures established
Provider by your data network to connect to another network. At their prompt, type:
311020256131 to access the PIES.
Additional
Information
A PIES user guide is available and may be obtained free-of-charge either by
leaving a message on the system addressed to "Sysop," by writing the above
address, or by calling one of the hotlines.
A-5
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OzonAction
Information
Clearinghouse
Through ICPIC, it is also possible to access the OzonAction Information
Clearinghouse (OAIC) which provides technical, programmatic, and
policy options for phasing out the use of Ozone Depleting Substances (ODS)
controlled under the Montreal Protocol. As a provision of the 1987 Montreal
Protocol, UNEP was charged with the establishment and management of an
international clearinghouse for reduction alternatives to the use of
chlorofluorocarbon (CFC) and halon families. The primary CFC/halon source ares
addressed by the OAIC include:
Aerosols, sterilants, miscellaneous uses, and carbon tetrachloride
Foams
Halons
Methyl bromide*
Refrigeration, air conditioning, and heat pumps
Solvents, coatings and adhesives.
EPA and PPIC are working closely with UNEP to develop and maintain this
system. The clearinghouse provides ICPIC and PPIC users with information on
ODS international experts, country phase out programs, ODS technology
alternatives, UNEP technical option reports, international publications on ODS
alternatives, chemical properties data bases, and industry case studies. The
clearinghouse is specifically designed for Article 5 country users but may be
accessed by others in developed or developing areas worldwide to exchange
information. UNEP strongly encourages the submission of any information about
the reduction and/or elimination of ODS in industrial applications. UNEP may be
contacted at the address provided above.
* Although methyl bromide i> not currently controlled under the Montreal Protocol, information on thi* chemical is being collected by the OAIC
due to increased interest U this substance.
A-6
-------
APPENDIX B
CASE STUDY FORMAT GUIDELINES
-------
-------
Guidelines for Case Study
Submissions to PIES
The PPIC is constantly in search of new information describing
how companies or organizations successfully prevent pollution
generation. This information is useful to others who are faced
with similar waste generation problems, but who need more
practical information about technology, method, or cost options.
The PPIC has helped design a case study format to make this
information available to its users in a concise, yet useful manner.
By sharing this case information with each other, PIES users
contribute to the improvement of our common environment.
If you have case studies that describe useful pollution prevention
technologies, methods, or approaches, please consider submitting
them to PIES' case study data base. The guidelines in this appen-
dix are intended to assist abstractors in preparing case studies
with the format required for the PEES system—please follow
them closely.
Once the PPIC has received your submissions, the case studies
will undergo engineering/technical reviews, quality assurance
checks, and style/format review. This review process will be
conducted by a combination of the following organizations:
PPIC
ICPIC
UNEP Cleaner Production Industry Working Groups
American Institute for Pollution Prevention (AIPP)
Illinois Hazardous Waste Resource Information Center
(HWRIC)
During the review process, you may be contacted by members of
the review teams to supply additional/missing information or to
clarify statements.
B-l
-------
You may submit potential case studies by uploading a text file to
the PIES (See "PIES File Transfer" section) or by transmitting
them to the PPIC by mail or facsimile.
PPIC
c/o SAIC
7600-A Leesburg Pike
Falls Church, Virginia 22043
Telephone: (703)821-4800
Fax: (703) 821-4775
B-2
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Case Study Format Guidelines
1.0 Headline: A short attention-getting phrase or sentence
highlighting the significance of the case study. The
headline should include industry or process, waste type,
waste volume/toxicity reduction, and pollution preven-
tion techniques. Describe quantitatively the problem
that was solved.
2.0 SIC Code and/or ISIC Code: Four-digit Standard
Industrial Classification code(s) that best describe the
industry segment(s) referenced by the case study. Em-
ploy the highest level of specificity (i.e., use three- or
two- digit SIC/ISIC codes if information does not allow
more detailed identification). Use as many SIC/ISIC
codes as are relevant to the subject study; however, the
primary SIC/ISIC code should always be the first code
listed. Precede all International SIC codes with "I"
(e.g., 12261).
3.0 Name and Location of Company: The name and
location of the facility that implemented the case study.
Include address if possible (street, city, state or prov-
ince, country, and postal code).
4.0 Pollution Prevention Category: A brief description of
the principle(s) behind the pollution prevention technol-
ogy referenced in the case study, such as:
• Periodic assessments
• Process/equipment modification
• Recycling, reuse, and reclamation
• Material/product substitution
• Training and supervision
• Housekeeping
• Production planning and sequencing
• Waste segregation and separation.
B-3
-------
5.0 Case Study Summary: Summarize information, to the
level of detail provided in the case study, in the follow-
ing areas:
5.1 Process and Waste Information: A description
of the relevant original manufacturing process or
area of the plant to which the pollution prevention
technique applies, physical state of the target
waste streams (solid, liquid, gas, or sludges),
changes in the process resulting from the pollution
prevention technique, and a description of any
positive or negative effects on the wastes, prod-
ucts, or production rate after implementing the
new technology. Include any changes in:
• Products or production rates resulting from
the application
• New or existing waste stream generation and
composition
• New or existing raw materials and consump-
tion rates
• Energy usage
• Operating procedures.
5.2 Scale of Operation: A description of the size of
the process or operation. If possible, include
quantitative information on the amount of product
being produced or manufactured and the amount
of waste being generated.
5.3 Stage of Development: A one-line description of
the .stage of development the pollution prevention
technique was in at the time of the case study
(e.g., planning stage, bench test, pilot state, or
fully implemented). Indicate whether quantitative
figures are estimated or based on actual produc-
tion.
5.4 Level of Commercialization: An indication of
whether the technology or process was commer-
cially available at the time of the case study.
Indicate whether or not the equipment and/or
materials were readily available, or if they were
specifically designed for this application.
B-4
-------
5.5 Material/Energy Balances and Substitutions
(optional): A tabulation of quantitative changes ,
in material generation and use prior to and result-
ing from the pollution prevention technique.
Include in the following table infonnation for
each waste stream or product, and designate
"N/A" when information is not available (provide
units of measurement for all numerical data):
Material Category
Waste Generation:
Feedstock Use:
Waster Use:
Energy:
Qty. Before
Qty. After
6.0 Economics1: A summary of the costs and savings
reported in the case study. Include dates and currencies
for all economic data reported.
6.1 Investment Costs: A summary of all capital
costs and a detailed description of the purchased
item(s) or service. Include any specifications (i.e.,
number, size, capacity, etc.) for each item used.
6.2 Operational and Maintenance Costs: Changes
in operational and maintenance costs (per month
or year) and changes in personnel or hours re-
quired.
6.3 Payback Time: The approximate payback period
for the particular pollution prevention technology
used in the case study (total investment/net/
savings/year).
7.0 Pollution Prevention Benefits: A detailed discussion
of the benefits resulting from the pollution prevention
technique, including, but not limited to:
• Economic benefits (include source of sav-
ings, e.g., reduced feedstock)
• Improved public relations
• Changes in regulatory compliance.
B-5
-------
Indicate, if possible, what factors were the driving force
behind implementing the technique.
8.0 Obstacles, Problems, and/or Known Constraints
(optional): A description of the technical constraints
that could prevent implementation of the technology
(e.g., physical, chemical, or biological limits of a manu-
facturing or treatment process). Discuss any regulatory
barriers in implementing the technology and indicate
what other problems were encountered during imple-
mentation of the technology.
9.0 Date Case Study Was Performed: The actual data the
pollution prevention measures were initiated.
10.0 Contacts and Citation
10.1 Type of Source Material: The type of source
material abstracted:
• Book or chapter
• .Journal or journal article
• Organizational report
• Conference proceedings
• Unpublished material
• Other (specify).
10.2 Citation: Citation for the document abstracted,
including: author(s); title of book, journal article,
or proceedings; volume; number, and month and
year of publication (see the Chicago Manual of
Style for appropriate formats). In addition, if the
document is available through NTIS, enter the
NTIS number.
10.3 Level of Detail of the Source Material: An
indication of whether or not additional detail is
available in the source document for this case
study (applicable only for documents that are
publicly available). Indicate what additional
information is available (e.g., process, waste,
etc.).
B-6
-------
10.4 Industry/Program Contact and Address: The
name, address, and phone number of the person
who can be reached for further information
concerning the case study. Authorization must be
given by the contact prior to including their name
in this field.
10.5 Abstractor Name and Address: The name,
organization, and address of the person preparing
the case study abstract
11.0 Keywords: Descriptive keywords selected from the
ICPIC keyword list2 for each of the following catego-
ries:
11.1 Waste Type: The conventional waste(s) that is/
are acted on by the pollution prevention option,
not the waste(s) generated after implementing the
pollution prevention techniques.
11.2 Process Type/Waste Source: The original
industrial process(es) or sources of the waste(s)
that is/are modified by the pollution prevention
technique.
11.3 Waste Reduction Techniques: The techniques
that were implemented at the facility and are
principally responsible for reducing waste genera-
tion.
11.4 Other Keywords: Other key words, as appropri-
ate, that accurately describe the case study and
assist users in locating this abstract, including:
• Environmental media (air, water, soil)
• Product names
• Feedstocks
• Special incentives
• Geographical/institutional keywords (Italy,
Ruhr Valley, USDA, etc.).
Use as many keywords as are necessary to accurately
describe the case study in each category. If ideal key-
B-7
-------
words are not found in the keyword list, please add new
ones to the list.
12.0 Assumptions: A listing of any assumptions used when
abstracting. Reference the sections of the abstract that
relied upon the assumption. Any discrepancies encoun-
tered in the source document should also be presented.
13.0 Peer Review: An indication of whether or not the
source document has gone through a technical peer
review process. Indicate: Yes, No, or Unknown.
1 Disclaimer: economic data will vary due to economic climate,
varying governmental regulations, and other factors.
2 A list of keywords can be obtained by contacting the PPIC or
leaving a message to the PIES SYSOP.
Note: Samples of completed case studies are available for
guidance in developing your own case study. To receive samples,
contact the PPIC.
B-8
_
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B\DIV834\570FMPPC\APPENPK.C
APPENDIX C
FOREIGN CURRENCY EXCHANGE RATES
-------
-------
FOREIGN CURRENCY EXCHANGE RATES
AS OF JUNE 30, 1992
FOREIGN CURRENCY RATES jj
(Highlighted currencies are associated with case studies located in the compendium) ||
COUNTRY
Afghanistan
Algeria
Angola
Antigua
Argentina
Australia
Austria
Azores
Bahamas
Bahrain
Bangladesh
Barbados
Belgium
Bolivia
Botswana
Brazil
Brunei
Bulgaria
Burkina Faso
Burma
Burundi
Cameroon
Canada
Cape Verde
Central African Rep.
Chad
CURRENCY NAME
afghani
dinar
kwanza
dollar
peso
dollar
Schilling
Portuguese escudo
dollar
dinar
taka
dollar
franc
boliviano
pula
cruzeiro
dollar
lev
CFA franc
kyat
franc
CFA franc
dollar
escudo
CFA franc
CFA franc
CURRENCY TO $1.00
55.00
22.04
29.92
2.700
.9890
1317
tt.48
134.9
1.000
.3769
38.91
2.040
: ' - " ' "„ '53.55
3.840
2.132
2910.0
1.612
22.70
274.0
6.119
203.8
274.0
1.202
67.53
274.0
274.0
September 9, 1992.
C-l
-------
FOREIGN CURRENCY RATES
(Highlighted currencie* are associated with caie itudie* located in the compendium)
COUNTRY
Chile
China
Columbia
Congo
Costa Rica
Cuba
Cyprus
Czechoslovakia
Czechoslovakia
Denmark '"
Djibouti
Dominican Rep.
Ecuador
•Egypt
El Salvador
Equatorial Guinea
Estonia
Ethiopia
Fiji Islands
^ •>
Finland' ' /,-\-
France ' ' "-„ ';, \ '
Gabon
Gambia
Germany -' "'*'.., /„
Ghana
Greece
Grenada
Guatemala
CURRENCY NAME
: peso-"" "' -*"
yuan
peso
CF A franc
colon
peso
pound
komna
tuzex komna
krone
franc
peso
sucre
pound
colon
CFA franc
ruble
birr
dollar
* maHflra
/- franc, , ' ,
CFA franc
dalasi
,, , " , mark , -
cedi
"" ' ' ^ PfftCTITIM
dollar
quetzal
CURRENCY TO $1.00
660.6
5.480
660.6
274.0
129.7
.7402
.4589
28.47
8.400
i 6.283
176.8
12.79
1471.00
3.333
8.190
274.0
104.0
2.054
1.489
' 4.423
5.480
274.0
8.650
i -' , , , 1-631
410.0
i 193.5
2.700
4.990
September 9,1992.
C-2
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FOREIGN CURRENCY RATES ~ |
(Highlighted currenciei are associated wife case studies located in the compendium)
COUNTRY
1 Guinea
Guinea-Bissau
Guyana
Haiti
Honduras
Hong Kong
Hungary
Iceland
India
Indonesia
Iran
Iraq
Ireland
Israel
-;- - 'Italy
Ivory Coast
Jamaica
Japan , - -
Jordan
Kenya
Khmer Rep.
Korea
Kuwait
Laos
Lebanon
Lesotho
Liberia
Luxembourg
CURRENCY NAME \ CURRENCY TO $1.00
franc
peso
dollar
gourde
lempira
dollar
forint
krona
rupee
rupiah
rial
dinar
pound.
shekel
lira
CFA franc
dollar
yen
dinar
shilling
riel
won-
dinar
kip
pound
South African rand
dollar
franc
922.0
6232.0
123.0
9.660
5.480
7.738
78.80
57.82
28.94
2027.0
71.00
.3100
.6099
2.414
; -' " i228.a
274.0
28.90
129.6
.6780
40.00
1650.0
784.0
.2908
715.0
1630.0
2.851
1.000
33.55
September 9, 1992.
C-3
-------
FOREIGN CURRENCY RATES
(Highlighted currencies ire associated with case studies located in the compendium)
COUNTRY
Madagascar
Malawi
Malaysia
Mali
Malta
Martinique
Mauritania
Mauritius
Mexico
Mongolia
Morocco
Mozambique
Nepal
Netherlands "
Netherlands Antilles
New Zealand
Nicaragua
Niger
Nigeria
Norway -. ;„„
Oman
Pakistan
Panama
Papua New Guinea
Paraguay
Peru
Philippines
Poland
CURRENCY NAME
franc
kwacha
ringgit
CFA franc
pound
French franc
ouguiya
rupee
peso
tugrik
dirham
metical
rupee
guilder
guilder
dollar
cordoba oro
CFA franc
naira
" , krone
rial
rupee
balboa
kina
guarani
inti
peso
zloty
CURRENCY TO $1.00
1938.0
3.168
2.523
274.0
.3165
5.480
78.40
15.65
3096.0
40.00
8.599
2345.0
47.57
*' "- i.836
1.780
1.867
5.050
274.0
19.20
'', ' "' ' !'6.353w
.3849
25.08
1.000
.9630
1445.0
1.130
26.70
13790.0
September?, 1992.
C-4
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FOREIGN CURRENCY RATES
(Highlighted currencies are associated with case .studies located in the compendium)
COUNTRY
Portugal
Qatar
Romania
Rwanda
Saudi Arabia
Senegal
Seychelles
Sierra Leone
Singapore
Solomon Islands
Somalia
South Africa
Spain
Sri Lanka
Sudan
Surinam
Swaziland
X" Sweden
Switzerland
Syria
Taiwan
Tanzania
Thailand:
Togo
Tonga
Trinidad & Tobago
Tunisia
Turkey
CURRENCY NAME
escudo
riyal
leu
franc
riyal
CFA franc
rupee
leone
dollar
dollar
shilling
sand
peseta
rupee
pound
guilder
emalangeni
krona
franc
pound
dollar
shilling
bant
CFA franc
pa'anga
dollar
dinar
lira
CURRENCY TO $1.00
134.9
3.639
371.0
121.3
3.750
274.0
5.150
510.0
1.631
2.865
3812.0
i - 2.851
101.7
43.28
94.05
1.770
2.851
5.866
1.487
11.20
24.93
298.5
25.47
274.0
1.319
4.244
.8887
6772.0
September 9, 1992.
C-5
-------
FOREIGN CURRENCY RATES
(Highlighted currencies ue associated with case studies located in the compendium)
COUNTRY
Uganda
trssR1 :,\\
United Arab Emirates
United. Kingdom
Uruguay
Venezuela
Vietnam
Western Samoa
Yemen
Yugoslavia
Zaire
Zambia
Zimbabwe
CURRENCY NAME
shilling
% * yff
\ ' ,-.- , ruble
dirham
; ' , pound sterling
new peso
bolivar
pisatre
tala
rial
dinar
zaire
kwacha
dollar
CURRENCY TO $1.00
1138.0
, -: - , L67i ;
3.673
,5541
2941.0
65.57
755.0
2.422
12.00
1211.00
185000.00
145.4
5.158
1. The USSR is now known as the CIS (Commonwealth of Independent States). Currently, the ruble is the basic
monetary unit of each individual republic within the CIS.
, 1992.
C-6
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B\DIV834\570F\IPPC\APPENDK.D
APPENDIX D
COMMON CHEMICAL ELEMENTS AND SYMBOLS
-------
r
-------
COMMON CHEMICAL ELEMENTS AND SYMBOLS
Element
Aluminum
Antimony
Arsenic
Barium
Beryllium
Bismuth
Boron
Bromine
Parfmiifm
Calcium
Carbon
Chlorine
Chromium
Cobalt
Copper
Fluorine
Gold
Helium
Hydrogen
Iodine
Iron
Symbol
Al
Sb
As
Ba
Be
Bi
B
Br
Cd
Ca
C
Cl
Cr
Co
Cu
F
Au
He
H
I
Fe
Element
Lead
T.ithjuni
Magnesium
Manganese
Mercury
Molybdenum
Nickel
Nitrogen
Oxygen
Phosphorus
Potassium
Selenium
Silicon
Silver
Sodium
Sulfur
Tin
Titanium
Tungsten
Zinc
Symbol
Pb
Li
Mg
Mn
Hg
Mo
Ni
N
O
P
K
Se
Si
Ag
Na
S
Sn
Ti
w
Zn
D-l
-------
-------
B\DIY834\570FMPPC\APPENDK.E
APPENDIX E
BIBLIOGRAPHY
-------
-------
BIBLIOGRAPHY
BATTERY
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
Lead Battery Plates by Automatic Filling of Fixed Molds", Monograph ENV7WP.2/5/Add.70.
CEMENT PRODUCTS
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "Pollution and Waste Reduction by Improved Process Control," 1993,
pages 10-11. *
CHEMICAL MANUFACTURING
Catalogue of Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, page 14.
Catalogue of Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, page 22.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "New Product: Water-Based Adhesives," 1993, pages 24-25.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recovery of
Hydrochloric Acid from Incineration of Chlorinated Waste Products", Monograph ENV/WP.2/5/Add.30.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Dry-Phase
Neutralization of Alkylates Generated in the Production of Styrene", Monograph ENV/WP.2/5/Add.33.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Hydrogen
Washing by Potassium Carbonate in Ammonia Production", Monograph ENV/WP.2/5/Add.34.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
Ammonium Nitrate with Continuous Control of the Reaction and Degassing of the Resulting Water Vapors"
Monograph ENV/WP.2/5/Add.40.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Sodium
Phosphate Made From Phosphorous Sludge", Monograph ENV/WP.2/5/Add.74.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Manufacturing
of Chloral: Dehydration by Means of a Solvent", Monograph ENV7WP.2/5/Add.81.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Manufacturing
of Soda Chlorate by Electrolysis of Sodium Chloride with Graphite Anodes", Monograph
ENV/WP.2/5/Add.92.
E-l
-------
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
Hydrazine Hydrate through Oxidizing Ammonia with Bleach", Monograph ENV/WP.2/5/Add.93.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
Aluminum Fluoride with the Utilization of Waste Silica" Monograph ENV/WP.2/5/Add.ll2.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Sorption and
Recycling of Harmful Materials During the Production of Polyurethan (PUR) Block Soft Foam", Monograph
ENV/WP.2/5/Add. 117.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Use of
Anhydrite Formed in the Hydrogen Fluoride Production Process", Monograph ENV/WP.2/5/Add. 123.
Process Technology and Flowsheets, articles which appeared in Chemical Engineering over the last five years. V.
Cavaseao and Staff of Chemical Engineering eds., McGraw-Hill, New York, NY, 1979. Caprolactam from
Toluene without Ammonium Sulrate, Andrew Heath. Page 137.
Secteur Chimie Inorganique, Technologies Propres, Production du Chlorate de Sodium, Gouvemement du Quebec,
Ministre de PEnvironement, Gestion et Assainissement des Eaux, Revised June 1988. Source document is
in French.
UNEP Working Group On (Halogenated) Solvents. Reformatted by Douglas Martin, Science Applications
International Corporation, 7600-A Leesburg Pike, Falls Church, VA 22043
ELECTRICAL EQUIPMENT
Catalogue of, Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, page 35.
Siljebntt, Lars et al; Forebyggande Miljoskyddssstrategi och Miljoanpassad Teknik i Landskrona, Etapp 2. ISSN
0281-5753.
ELECTROELATING
Catalogue of Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, pages 42 and 96.
Clean Technology, Environmental Protection Technology Scheme, Department of the Environment, 2 Marsham
Street, London SW1P 3EB, 1989, page 2.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "Waste Reduction in Electroplating," 1993, pages 20-21.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Chromium Metal
Plating Followed by Rinsing and by Regeneration of Rinse Water on Ion Exchange Resins with Recycling",
Monograph ENV/WP.2/5/Add.73.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Copper-Plating
of Parts Followed by Electrodialysis: Recovery of Copper Contained in Rinsing Water", Monograph
ENV/WP.2/5/Add. 100.
E-2
-------
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "the Chemelec
Cell for Recycling of Metal in the Electroplating Industry", Monograph ENV/WP.2/5/Add.l01.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Rotalyt-Alutop"
Monograph ENVAVP.2/5/Add. 124.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "A Low-Waste
Electroplating Process of Aluminum in Non-Aqueous Solvent (Sigal-Process)", Monograph
ENV/WP.2/5/Add.l25.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "A No-Dump
Bath Using Trivalent Chromium for the Blue Passivation Process in the Galvanic Industry", Monograph
ENV/WP.2/5/Add.l26.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Use of Low-
Volume Rinsing in Surface Finishing, Electroplating Processes", Monograph ENV/WP.2/5/Add.l27.
Envirochrome Process Operating Guide. W. Canning Materials, Ltd., Birmingham, UK.
Fluid Bed Reactor in Practice, The, Advantages and Disadvantages, W.LJ. Janssen, Tijdschriift Voor
Oppervlaktetechnieken en Corrosiebestrijding. December 1989, Vol. 33, No. 12.
Membrane Electrolysis in Practice, J. Manders, Tijdschrift Voor Oppervlaktetechnieken en Corrosiebestrijding
January 1990, Vol. 34, No. 1, pages 14 - 16.
Reduced Water Consumption and Hazardous Waste, Jerome Kovach, Kinetico Engineering Systems, Inc.,
Newbury, Ohio.
Removal of Cations from Chromic Acid by Continuous Cleaning of Drag-Out Baths Through a Cation Resin and
Evaporation Before Reuse. Jan Ros, Bilthoven, Netherlands.
Secteur Revetement de Surface, Technologies Propres, Electrogalvanization et Zingage a Chaud, Gouvernement de
Quebeck, Ministre de 1'Environement, Gestion et Assainissement des Eaux, revised June 1988. Source
document is in French.
Title not given. B. Johnson, W. Canning Materials Ltd., Birmingham, UK.
Wastewater Problems in the Metal Industry: Results of Interviews with 48 Companies. W.H. Rulkens, Apeldoom,
Netherlands.
UNEP Workgroup Plant Visit, M. Stein, Bilthoven, Netherlands, December 1990.
FERTILIZER
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Comparison
Between Conventional and Low-Waste Nitric Acid Production Technologies", Monograph
ENV/WP.2/5/Add.lO.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
NPK Fertilizers Through the Nitro-Phosphate (ODDA) Process with Conversion of Calcium Nitrate and
Recirculation of Nitrogen and Phosphorous Effluents", Monograph ENV/WP.2/5/Add.ll.
E-3
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Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recovery and
Recycling of Ammonia Contained in Gases from Ammonium Nitrate Production", Monograph
ENV/WP.2/5/Add.29.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Continuous
Absorption of Fluorine-Containing Waste Gas", Monograph ENV/WP.2/5/Add.48.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Wastewater
Evaporation Process for Fertilizer Production Technology", Monograph ENV7WP.2/5/Add.62.
FOOD
Acid Purification Unit for Use on Concentrated High Temperature Pickling Liquor (Sulfuric Acid) Report, M.
Stein, Bilthoven, Netherlands.
Clean Technology, Environmental Protection Technology Scheme, Department of the Environment, London,
England, 1989, pages 6 and 21.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "Recovery of Protein from Potato Starch Effluent,* 1993, pages 12-13.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Semi-Closed
or Closed Silicon/Ferrisilicon furnaces with Gas Cleaning and Recovery", Monograph ENV/WP.2/5/Add. 12.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Mechanical
Peeling of Vegetables/Fruits", Monograph ENV/WP.2/5/Add.35.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Extraction of
Potato Starch with Recovery and Use of Proteins in Internal Liquid", ENV/WP.2/5/Add.39.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Demineralization
of Beet Juice with Reuse of filtrates', Monograph ENV/WP.2/5/Add.41.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "The Ahamet
Process for Wastewater Purification", Monograph ENV/WP.2/5/Add.43.
Compendium, on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Treatment of
Juice from Sauerkraut Fermentation and Production of Yeast in this Effluent", Monograph
ENVAVP.2/5/Add.49. '
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Production of
Lactoserum Powder with Recovery of Powder and Heat from Discharged Air", Monograph
ENV/WP.2/5/Add.50.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Manufacture
of Preserved Pates with Recovery of Fats by Centrifugation", Monograph ENV7WP.2/5/Add.51.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Manufacture
of Fats by Continuous Melting with Recovery of Fats and Proteins from Wastewater", Monograph
ENV/WP.2/5/Add.78.
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Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Dry Extraction
of Potato Starch Substitute", Monograph ENV/WP.2/5/Add.84.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Pickling Steel
Plates with Chloihydric Acid, After Hot Rolling: Recovery and Regeneration of Acid Pickling Baths",
Monograph ENV/WP.2/5/Add.96.
Process Technology and Flowsheets, articles which appeared in Chemical Engineering over the last five years. V.
Cavaseno and staff of Chemical Engineering eds., McGraw-Hill, New York, NY, 1979. High-Carbon
Ferrochrome Route Slashes Power Use, Kazuo Ichikawa, page 110.
Secteur Agro-Alimentaire, Technologies Propres, Abattage de Volailles, Gouvernement de Quebeck, Ministre de
rEnvironement, Gestion et Assainissement des Eaux, May 1989. Source document is in French.
Secteur Agro-Alimentaire, Technologies Propres, Production Fromagere, Gouvernement du Quebec, Ministre de
rEnvironement, Gestion et Assainissement des Eaux, revised June 1988. Source document is in French.
Water and Raw Materials for Non-Waste Technology Processes, Erik Rud Madsen, Technical Research Center of
Finland, Espoo, Finland, June 20-23, 1988, pages 51-62.
IRON AND STEEL
Catalogue of Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, pages 63, 64, 66, and 67.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Flain, Clean
Technology Coordinator for DoE, "Gas Phase Heat Treatment of Metals," 1993, pages 4-6.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Water Closure
System in Paper Mills", Monograph ENV/WP.2/5/Add.28.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "CSM-Biothane
U.A.S.B. Process for Anaerobic Waste Water Treatment", Monograph ENV/WP.2/5/Add.75.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Integrated
Manufacture of Pulp and Lime Carbonate Paper with Effluent Recycling and Sludge Burning", Monograph
ENV/WP.2/5/Add.80.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Paper/Board
Making with Closed Water Systems", Monograph ENV/WP.2/5/Add.88 and Add.89.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Filler Clay
Recovery by wet Air Oxidation of Sludge (Zimpro Process)", Monograph ENV/WP.2/5/Add.91.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Desilication of
Spent Liquors Derived from Aldaline Pulping of Nonwood Fibers", Monograph ENV/WP.2/5/Add.llO.
Environmental Management in the Finnish Pulp and Paper Industry, Seppo Ruonala, Sound Environmental
Management in the Pulp and Paper Industry, Seminar Papers, and Documents, May 14-17, 1986, pages 65-
75.
E-5
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Old Pulps For New, D. Pride, Paper, November 6, 1990, page 28.
LEATHER TANNING AND FINISHING
Activated Carbons from Chromium Tanned Leather Waste. In: Pyrolysis and Gasification, Ed. Ferrero GL,
Elsevier Pub. Ltd., 1989, pages 439-443.
B Lederkongress Proceedings, W. Pauckner, Budapest, 1986.
Barcelo ACO, Tesis Doctoral Universidad de Alicante, 1988.
Biological Conversion of Low Grade Fats, Thesis by Rydin S. Lincentiate, 1989.
Biomethanisation des Residus de Tannerie: Une Experience Industrielle, M. Aloy, R. Mermet, and I. Sanejouand,
Industrie du Cuir, 1987, (5), pages 23-27.
Biomethanisation des Residus de Tannerie: Une Experience Industrielle, M. Aloy, R. Mermet, and J. Sanejouand,
JALCA, 1989, 84, (4), pages 97-109.
Bleu ou Blanc, A. Balas, Industrie du Cuir, 1988 (8802) pages 27-29.
Challenge of ICC (Instant Colour Concept) - Zero Stock Level and Zero Delay, B. Vulliennet, B. Vitteau, and G.
Gavend, IULTCS Conference Proceedings, Philadelphia, PA, 1989, L-14.
Challenge of ICC (Instant Colour Concept) - Zero Stock Level and Zero Delay, B. Vulliennet, B. Vitteau, and G.
Gavend, Industrie du Cuir, 1988, 8807, pages 81-83.
Clean Technology, Environmental Protection Technology Scheme, Department of the Environment, London,
England, 1989, page 4.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "Chrome Recovery and Recycling in the Leather Industry," 1993, pages
6-8.
Combustion of Chrome Shavings Report, Danish Technological Institute, 1987.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recovery and
Reuse of Trivalent Chromium in the Learner Tanning Industry", Monograph ENVAVP.2/5/Add.54.
Compensation of Chrome by Other Tanning Agents, A. Zissel et al, Leder, 1980, 31, (2), pages 17-24.
Eine Unerwartete Beobachfung bet der Gerbung mit Pfianzengerbstoffen, E. Boziaris, L. Tonigold, and E.
Heidemann, Leder 39 (1988), pages 236-238.
Eiweiss und Leder, Technische Hochschule Darmstadt, Prof. Dr. E. Heidemann, Institut fur Biochemie, Abtly.
Elimination of Salt Pollution: coupling of Cooling of Hides and Wet White Technology, B. Vulliennet and G.
Gavend, JSLTC, 1988, 72, 2, pages 68-72.
Essais en Station Pilote d'Ultrafiltration de Bains Residuaires de 1'Industrie du Cuir, B. Vulliermet et al, Technicuir,
1976, Vol. 6, pages 94-99.
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Fat Liquoring of Leather Using Enzyme Treated Gluestock Fat, Rydin S. Licentiate, Internal Report, 1988.
Iced Hides Are Better, P. Schroeder, 1990, 192, pages 34-37.
lad Cuir, January 1990, page 30.
IULTCS Conference Proceedings, 20th Congress, Philadelphia, Pennsylvania, I.P. Tate» 1989.
JULICS Conference Proceedings, W. Pauckner, Venice, 1983.
Leather Tanning Process Using Aluminum ffl and Titanium IV Complexes, A.D. Covington.
Leder, E. Heidemann and B. Balstros, 1984, Vol. 35, pages 186-189, Lutan V (BASF), TI/P 3042d.
Leder, 1988, A. Hein, P. Herrera, and E. Heidemann, pages 141-145.
Leder, December 1989, page 251.
Leder, June 1990, page 103.
Newer Practical Experiences with Liquid Dyestuffc in Drum Dyeing, W. Muller and J. Westphal, Leder Haute
Markt, 1985, 37, pages 38-40/Bayer Information for the Leather Industry, 1985.
Nouvelle matiere Premiere pour 1'Industrie du Cuir, le BSS - Aspects Fondamentaux, R. Haran and M. Gervais-
Lugan, Industrie du Cuir, 1989 (8901), pages 28-32.
OCS Chiller, The, G. Mattson and T. Tomoser, Leather Manufacturer, 1988, 4, pages 24-26.
Production of Wet White, E. Heidemann et al, Leder 1982, Vol. 33, pages 131-136; 1985, Vol. 36, pages 170-175-
1986, Vol. 37, pages 221-224; 1987, Vol. 38, pages 71-75.
Separation des Proteines des Proteines des Dechets de Peaux Brutes par Technique Membrane, M. Dubois et al,
Technicuir, 1978, Vol. 4, pages 53-63.
Symposia Proceedings, W. Pauckner, Freiburg, 1989.
Tannages Based on Aluminum ffl and Titanium ffl Complexes, A.D. Covington, J. American Leather Chemical
Association, 1987, 82(1)1.
Tannery and Pollution, M. Aloy et al, CTC, 1976, page 307.
Tanning with Aluminia Salts, B. Bay et al, LMH 1985 (14) page 28.
Technical literature, Hude-Centralen, Denmark.
Unhairing and Tannage with the Penetrator, A. Petersen and H.P. Germann, Leder, 1989, 40, (9), pages 187-191.
Universal Use of Liquid Metal Complex Dyestufls, J. Westphal, Leder, 1983, 34, pages 148-151/Leder Haute
Markt, 1983, 29, pages 8-10.
VGCT Conference Proceedings, J. Westphal, Maastrickt, 1983.
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METAL PRODUCTS MANUFACTURING
Catalogue of Successful hazardous Waste Reduction/Recycling Projects", Energy Pathways, Inc., and pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, page 58.
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "Waste Reduction in Steelwork Painting," 1993, pages 22-23.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Continuous
Hardening and Zinc-Coating (Zinquench)", Monograph ENV/WP.2/5/Add.8.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recovery and
Recycling of Solvents from Vapors Originating from Priming and Painting of Aluminum Foils" Monograph
ENV/WP.2/5/Add.32.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Descaling of
Metal objects by Means of Vibration/Abrasion", Monograph ENV/WP.2/5/Add.36.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Cold Machining
with Recycling of Cutting Fluids After Ultraflltration", Monograph ENV/WP.2/5/Add.72.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Hardening of
Spinning Rings by a Dry Process on a Fluidized Bed", Monograph ENV/WP.2/5/Add.71.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Pickling of
Copper Parts: Electrolysis of Used Pickling Baths", Monograph ENV/WP.2/S/Add.97.
MINING
Cu/U Ore Leaching Route Cuts Pollution, Trims Costs, Gerald Parkinson, page 108.
Process Technology and Flowsheets, articles which appeared in Chemical Engineering over the last five years. V.
Cavaseno and staff of Chemical Engineering, McGraw-Hill, New York, NY, 1979.
NONFERROUS METALS
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Outokumpu
Ferrochrome Process", Monograph ENV/WP.2/5/Add.9.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Mechanical
Descaling of Wire Rods by a Dry or Wet Process", Monograph ENV/WP.2/5/Add.68.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Pickling of
Copper Wire With Alcohol", Monograph ENV/WP.2/5/Add.69.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Melting of Brass
Turnings In and Electric Furnace With Previous De-Oiling of Turnings and Heat Recovery", Monograph
ENV7WP.2/5/Add.95.
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Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Transforming
Blends Into Zinc Oxide by Roasting With Fabrication of HjSO, Through Catalysis of Roasting Gases and
Integrated Treatment of Tail Gases", Monograph ENV/WP.2/5/Add.98.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Continuously
Operating Direct Lead Smelting Process (QSL)", monograph ENV/WP.2/5/Add.ll4.
NONMETALLIC MINERAL PRODUCTS
Clean Technology, Environmental Protection Technology Scheme, Department of the Environment, London,
England, 1989, page 23.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Use of Quarry
Wastes or Waste Glass", Monograph ENV/WP.2/5/Add.l.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recycling of
Water From Manufacturing of Asbestos/Cement Panels and Pipes", Monograph ENV7WP.2/5/Add.31.
PETROLEUM REFINING
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Utilization of
Process Condensate resulting from Petroleum Refining", Monograph ENV7WP.2/5/Add.45.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Pre-conditioning
of Petroleum Residues for Subsequent Catalytic Processing and Manufacture of New Material: Petroleum
Asphaltite", Monograph ENV/WP.2/5/Add.46.
PLASTIC PROCESSING
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Recovery of
Mixed Plastic Waste Products", Monograph ENV/WP.2/5/Add.2.
Compendium on Low and Noa-Waste Technology, United Nations Economic and Social Counsel, "Surface
Treatment of Plastic Materials in a Sulfochromic Solution with Regeneration and Recycling of the Solution",
Monograph ENV7WP.2/5/Add.38.
PRINTING
Clean Technology, Environmental Protection Technology Scheme, Department of the Environment, London,
England, 1989, page 14.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Reuse of
Printing Ink for Newspaper Production", Monograph ENV/WP.2/5/Add.l09.
PULP AND PAPER
43rd All India Textile Conference Proceedings, December 1986, Bombay, India.
Advances in Environmental Control, Tappi Journal, April 1991, pp. 18-22.
Advances in pulping, Tappi Journal, October 1989, pp. 11-16.
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Advances in pulping, Tappi Journal, November 1988, pp. 16-20.
Ahlgren, L., Kraft pulp: Cleaner still by year 2000, PPI, April 1991, pp. 59-61.
ALBAZYME, Pulp and Paper enzymes, Biopulp International, brochure, 4 p.
Alkaline Peroxide Mechanical Pulping System, Sprout-Bauer, Combustion Engineering, Brochure, 7 p.
D'Almeida, M.L.O. and Nahuz, M.A.R., O setor celulosico-papeleiro no Brasil e o meio ambiente, Institute de
pesquisas Tecnologicas, 6 p.
Althouse, E.B., Bostwick, J.H. and Jain, D.K., Using hydrogen peroxide and oxygen to replace sodium
hypochlorite in chemical pulp bleaching, Tappi Journal, June 1987, pp. 113-117.
APCEL Pulp Mill Redevelopment Project, Draft Environmental Impact Statement, Prepared for Apcel Pty Ltd by
Kinhill Engineers Pty Ltd, June 1990, 17 p.
ARACRUZ: A forestry and pulp enterprise on the east coast of Brazil, 7 p.
Ancruz celulose: environmental policy, 2 p.
Araki, M. and Hosomi, M., Using bacteriophage for slime control in the paper mill, Tappi Journal, August 1990,
pp. 155-158.
A SYTYKE research programme report, will be published in 1993, in Finnish, summaries in English, German and
Swedish.
D'Avila, L. e lima, N.R., Papel e celulose, Riocell muda de atitude e investe em meio ambiente, Saneamento
ambiental, Outubro de 1990, No 9, pp. 22-25.
Axegird, P., Substituting chlorine dioxide for elemental chlorine makes the bleach plant effluent less toxic, Tappi
Journal, October 1986, pp. 54-59.
Aziz, S., McDonough, T., Thompson, N. and Doshi, M.R., Solvent pulping - Promise and programs, Tappi
Journal, February 1988, pp. 251-256.
Aziz, S. and Sarkanen, K., Organosolv pulping- a review, Tappi Journal, March 1989, pp. 169-175:
Barbe, M.C., Kokta, B.V., Lavallee, H-C. and Taylor, J., Aspen pulping: A comparison of Stake explosion and
conventional chemi-mechanical pulping processes, Pulp & Paper Canada, 91:12 (1990), pp. 142-151.
Basta, J., Holtinger, L., Hook, J. and Lundgren, P., Reducing levels of absorbable organic halogens (AOX), Tappi
Journal, April 1990, pp. 155-160.
Beaudry, R.N., Towards a Zero Effluent PGW Pulp Mill, 77th Annual Meeting, Technical Section, Canadian Pulp
& Paper Association, January 1991, Montreal, Canada, pp. B339-B340.
Berry, R.M., Fleming, B.I., Berndt, G. and Williams, G., Papricycle - a mill proven process for saving bleach
plant caustic and steam, Tappi Journal, February 1989, pp. 109-113.
Bjorkman, A. and Warnqvist, B., Basic processes in gasification/burning of kraft liquors, Pulp & Paper Canada,
89:11 (1988), pp. 56-62.
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Black, N.P., ASAM alkaline sulfite pulping process shows potential for large-scale application, Tappi Journal, April
1991, pp. 87-93.
Black, N.P., Success convinces Millar Western to use alkaline peroxide process for bleached
chemithermomechanical pulp at Meadow Lake, Tappi Journal, September 1990, pp. 99-101.
Blanchette, R.A., Burnes, T.A., Eerdmans, M.M. and Akhtar, M., Evaluating Isolates of Phanerochaete
chrysosporium and Ceriporiopsis subvermispora for Use in Biological Pulping Process, Holzforschune Vol
46, 1992, No. 2, pp. 109-115.
Bleached flax pulp mill, prospectus, Arbokem Inc., October 1990, 25 p.
Bowen, I.J. and Hsu, J.C.L., Overview of emerging technologies in pulping and bleaching, Tappi Journal
September 1990, pp. 205-217.
Breakthrough in pulp bleaching - Completely chlorine-free pulp from Finland, Views on Finnish technology,
Technology development centre Finland, 1992, p. 16.
Brewer, G,, Quiet, cozy and green: recycled mixed paper panels, Resource Recycling, January 1991, pp. 62-69.
Brower, P.H., The relationship between zeta potential and ionic demand and how it affects wet-end retention Tappi
Journal, January 1991, pp. 170-179.
Calzada, J.F., de Arriola, M.C., Rolz, C. and Valladares, J., Treatment of banana stem juice: methane production
and effluent purification, Environmental technology letters, Vol. 9, 1988, pp. 785-790.
Calzada, J.F., Valladares, J., Rolz, C. and Zabala, J., Anaerobic digestion in the integrated utilization of banana
wastes, Poster papers, Fifth International Symposium of Anaerobic Digestion, 1988; A Tilche & A Rozzi
(eds), pp. 469-471.
Catalogue of Successful Hazardous Waste Reduction/Recycling Projects, Energy Pathways, Inc., and Pollution
Probe Foundation, prepared for Industrial Programs Branch, Conservation & Protection Environment,
Canada, March 1987, page 65.
Chaudhuri, P.B., Explosion pulping - exploratory trials, Tappi Journal, December 1989, pp. 196-200
de Choudens, C., Angelier, R., Devic, M. and Kervennal, J., Chemithermomechanical pulps at high level of
brightness obtained by the bivis process associated with a sulfonation in reducing medium, Paper! ja Puu -
Paper and Timber 72 (1990):3, pp. 248-252
Cockram, R., Demand from papermakers will grow, PPL June 1991, pp. 49-51
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Closed Cycle
Technology for Bleached Kraft Pulp Mills", Monograph ENV/WP.2/5/Add.5.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Pressurized
Stone Grinding for Mechanical Pulp Production", Monograph ENV/WP.2/5/Add.6.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Technological
Process of Dry Bark-Stripping of Wood in Barking Drums", Monograph ENV/WP.2/5/Add.44.
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Crawford, R.J. and Stryker, M.N., Factors that affect the generation of chloroform in bleaching, Tappi Journal,
November 1988, pp. 151-159.
Dahlbom, J-, Olm, L. and Teder, A., The characteristics of MSS-AQ pulping-a new pulping process, Tappi
Journal, March 1990, pp. 257-261.
Dahlmann, G. and Schroeter, M.C.,The Organocell process- Pulping with the environment in mind, Tappi Journal,
April 1990, pp. 237-240.
Ballons, V.J., Hoy, D.R., Messmer, R.A. and Crawford, R.J., Chloroform formation and release from pulp
bleaching, Results of field measurements, Tappi Journal, June 1990, pp. 91-95.
Der richtige Weg zur umweltfreundlichen Zellstofferzeugung, Kraftanlagen Heidelberg, brochure, 8 p.
Devic, M., Kervennal, J. and Lachapelle, R.C., CTMP - Improved brightness and strenght by sulfonation in
presence of a reducing agent,. Tappi Proceedings, 1988 Pulping Conference, New Orleans, Oct. 30 - Nov.
2, Book 2, pp. 491-495.
Dillner, B., Larsson, L. and Tibbling, P., Nonchlorine bleaching of pulp produced by the modified continuous
cooking process, Tappi Journal, August 1990, pp. 167-172.
Dimmel, D.R. and Bozell, J.J., Pulping catalysts from lignin, Tappi Journal, May 1991, pp. 239-241.
Dominguez, J.L. and Valladares, J.L., Obtencion de pulpas a partir de tres variedades de eucaliptus utilizando como
licor de coccion mezclas de etanol-aqua-sosa en presencia de antraquinona, pp. 143-146.
Durai-Swamy, K., Warren, D.W., and Mansour, M.N., Pulse-Enhanced Indirect Gasification for Black Liquor
Recovery, International Chemical Recovery Conference, 3.-6.4.1989, Ottawa, Canada, pp. 217-222.
Empie, H.J., Alternative kraft recovery processes, Tappi Journal, May 1991, pp. 272-276.
Environmental High-Technology from Finland, prepared by Mexpert Consulting Engineers Ltd. for the Ministry
of the Environment, Helsinki 1987, pp.23-24.
Environmental high-technology from Finland, Prepared by Mexpert Consulting Engineers Ltd. for the Ministry of
the Environment, Helsinki 1987, pp. 33-36.
Fomari, M.C., Aracruz assume compromisso ambiental a nivel international, Saneamento ambiental, Junho/Julho
de 1991, No 14, pp. 12-15.
Fomari, M.C., Bahia Sul usa processes modernos para cpntrolar impacto ambiental, Saneamento ambiental,
Junho/Julho de 1991, No 14, pp. 16-19.
Fomari, M., Papel e celulose, Ripassa: tratar os efluentes para evitar contaminacao, Saneamento ambiental,
Outubro de 1990, No 9, pp. 20-21.
Fomari, M., Papel e celulose, Suzano otimiza a producao e gera menos residues, Saneamento ambiental, Outubro
de 1990, No 9, pp. 14-16.
Forsstrom, A., Aspa Bruk: Forst med klorfri sulfatmassa, Svensk Papperstidning/Nordisk Cellulosa, Nr 3, 1992,
pp. 20-21.
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Possum, G. and Marklund, A., Pretreatment of kraft pulp is the key to easy final bleaching, Tappi Journal,
November 1988, pp. 79-84.
Fuchs, K., Rimpi, P. and Brown, C., Chemical Recovery System for an ASAM Mill, Tappi Proceedings, Pulping
Conference, Noveaber 1991, pp.259-270.
Fuchs, K., The ASAM Process, Kraftanlagen Heidelberg, 13 p.
Fu-ting Ma, Fa-bin Jiao, Pilot plant test run of desilication for alkaline wheat straw pulping black liquor,
Proceedings of the Workshop on Environmental Aspects of Non-Wood Fibre Pulp and Paper Manufacture,
Vol. H, UNEP Regional Office for Asia and the Pacific, September 1987, pp. 478-487.
Galluch, R.J., Alternate Process for Bleaching Could Help in Reducing TOCls, Dioxin, Pulp & Paper, September
1989, pp. 145-147.
Garcia, O.L., Cuba-9 project develops bagasse CMP, PPI, March 1989, pp.49-50.
Germer, E.I., Oxygen-alkaline delignification catalysis, Ligno-Cellulosics- Science, Technology, Development and
Use, (Ed.) J.F.Kennedy, G.O.Phillips, P.A.Williams, Ellis Horwood 1992, pp. 227-237.
Granfeldt, T., Danielsson, O., Norden, S. and Rydberg, K.G., Towards effluent-free production of bagasse and
eucalyptus pulps for newsprint, Tappi Journal, November 1988, pp. 54-59.
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WASTE RECLAMATION SERVICES
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Foster Wheeleir
Power Products Limited Pyrolysis Technology for Energy from Used Tires", Monograph
ENV/WP.2/5/Add.82.
MISCELLANEOUS
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Retrofitting Oil
Fired Furnaces", Monograph ENV/WP.2/5/Add.4.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Nord-Aqua Low
Temperature Waste Heat Desalination", Monograph ENV/WP.2/5/Add.7.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Energy Saving
and Pollution Prevention in Adhesive Tape Ovens Using Gas-Fired Solvent Incinerators and Waste Heat
Recover", Monograph ENV/WP.2/5/Add.90.
Compendium on Low and Non-Waste Technology, United Nations Economic and Social Counsel, "Side Stream
Separator Control of Particulate Missions", Monograph ENVAVP.2/5/Add.l02.
Hazardous Waste Reduction Program, Oregon Department of Environmental Quality, "Guidelines for Waste
Reduction and Recycling: Metal Finishing, Electroplating, and Printed Circuit Board Manufacturing," July
1989.
Proceedings on the International Conference on Pollution Prevention: Clean Technologies and Clean Products, "The
Environmental Challenges of the 1990*s," EPA/600/9-90/039 as referenced in "Facility Pollution Prevention
Guide," EPA Office of Solid Waste and Office of Research and Development (Risk Reduction and.
Engineering Lab).
E-22
-------
CASE STUDIES OF THE REUSE AND RECYCLING OF POST-CONSUMER WASTE
Cleaner Production Worldwide, United Nations Environmental Programme, produced by Robert Plain, Clean
Technology Coordinator for DoE, "De-inking Process for Waste Paper," 1993, pages 16-17.
E-23
-------
-------
KEYWORDS INDEX
-------
-------
KEYWORDS INDEX
Abrasive Cleaning 2-154
Abrasives 2-82
Absorption 2-70
Acid Catalysis 2-167
Acid Purification 2-104
Acid Reclamation 2-104
Acid Treatment 2-242
Acidic Wastewaters 2-67
Acoustic Panels 3-12
Activated Carbon 2-162
Activated Sludge 2-74, 2-319
Adhesive 2-295
Agricultural Processing 2-76
Agricultural Residues 2-280
Agriculture 2-87, 2-93
Ahamet Process , 2-74
Air Drying 2-162
Air Emissions 2-8, 2-145, 2-161, 2-175
Airless Paint Spray 2-158
Albazyme ' 2-267
Alcohol 2-165, 2-280
Alcohols 2-218, 2-221, 2-286
Alkali Recovery 2-303
Alkaline Degreasing 2-161
Alkaline Solution . . 2-67
Alkaline Straw Pulping 2-307
Alkaline Wheat/Rice Straw Pulping 2-303
-------
Alternative Chemicals 2-145
Alternative Kraft Process 2-316
Alternative Method to Use Sugarcane Bagasse 2-292
Alternative Process 2-137
Alternative Recycling of Cement Sack Papers 3-15
Alternatives Evaluation 2-93
Aluminum 2-51, 2-52, 2-112
Aluminum Complex 2-131
Aluminum Fluoride 2-11
Aluminum Sulphate 2-116, 2-135
Ammonia 2-19, 2-71, 2-127, 2-139
Ammonium Nitrate 2-10, 2-73
Ammonium SulfiUe 2-25
Ammonium Titanyl Sulphate 2-133
Ammonium Vent Gas 2-72
Anaerobic Digestion 2-76
Anaerobic Lagoons 2-319
Anhydrite 2-13
Animal and Marine Fats 2-87
Annual Cost Savings ". 2-87, 2-359
Anthnquinone , 2-214, 2-286
AOX 2-255
AOX Elimination : 2-214
ASAM Pulping : 2-214
Asbestos 2-2
Asphaltite 2-171
Automotive 2-393
Bagasse 2-295
Bagasse Pulping 2-286
-------
Bamboo 2-310
Bamboo Black Liquor 2-310
Basic Wastewaters 2-16
Battery Plates ; 2-l
Beets 2-77
Bhutan 2-386
Binder 2-295
Biobleaching 2-252
Biological Reactor 2-319
Biomethanisation 2-108
Biotechnology 2-332
Bisulfite Pulping 2-185
Bivis Extruder 2-206
Black Liquor 2-299, 2-307
Black Liquor Recovery 2-310
Black Sulfur Dyeing 2-381
Blast Furnace 2-106
Bleach . - . . . 2-372
Bleach Plant .....' 2-248
Bleach Plant Effluent . . . . . 2-233, 2-242, 2-245, 2-255, 2-259, 2-262, 2-265, 2-270
Bleach Plant Waste Liquors 2-248
Bleach Plant Waste Water 2-252
Bleached Kraft Pulp 2-190, 2-271, 2-272
Bleaching 2-188, 2-189, 2-192, 2-224, 2-227, 2-236, 2-245, 2-255, 2-372
Bleaching Effluent 2_188 2-3l9
Blende 2-167
BOD/COD 2_137j 2_09
BOD/COD Reduction 2-114 2-129
Boilers 2-397
-------
Bolts, Nuts, Screws and Rivets 2-67
Brass Turnings 2-168
Brightness 2-206
Brine 2-21
Brownstock Washing 2-197
By-Product Recovery 2-346
By-products 2-295
Canada 2-16, 2-87, 2-93, 2-104
Caprolactam Manufacture 2-25
Carbon Adsorption 2-22, 2-62
Carbon Dioxide 2-114
Cascade Rinsing 2-62
Caustic 2-21, 2-265
Caustic Soda 2-348, 2-367
Cement 2-2
Cement Kiln Emissions 2-4
Cement Manufacturing 2-6
Centralized Layout 2-179
Centrifugation 2-83
Ceramic Additives 2-110
Cheese 2-93
Cheese Manufacturing 2-90
Chemelec 2-63
Chemical Alternatives 2-112, 2-114, 2-116, 2-131, 2-133, 2-141
Chemical Injection 2-137
Chemical Oxygen Demand 2-76
Chemical Pulp Mill 2-179
Chemical Pulp Mill Effluent 2-185
Chemical Pulping 2-188, 2-210, 2-214, 2-218, 2-221, 2-224, 2-233, 2-286, 2-295, 2-319
-------
Chemical Reclamation 2-110
Chemical Recovery 2-303
Chemimechanical Pulping 2-236
Chemithermomechanical Pulp 2-206
Chloral 2-23
Chlorate 2-12
Chloride (Salt) 2-118, 2-143
Chloride Reduction 2-44
Chlorinated Organic Material 2-233
Chlorinated Organics 2-194
Chlorination 2-227
Chlorine 2-16, 2-21, 2-23, 2-190
Chlorine and Sulphur-free Pulping 2-188
Chlorine Bleach 2-357
Chlorine Dioxide 2-227
Chlorine Reduction 2-40, 2-194
Chlorine-free 2-224
Chlorine-free Bleaching > . . 2-242, 2-252
Chromating 2-53
Chrome 2-53
Chrome Plating 2-44
Chrome Wastes 2-41
Chromium 2-131, 2-133, 2-141, 2-150
Chromium Alternatives 2-135
Chromium Compounds 2-112
Chromium Leather Tanning 2-149
Chromium Recycling 2-120, 2-123, 2-137
Chromium Wastes 2-147
Clay 2-100
-------
Cleaner Production Technique 2-262
Closed Cycle Mill 2-214, 2-248
Closed-Loop Water Recycle 2-392
Closed-Type Electric Furnace 2-106
Closed-Loop Systems 2-350
Closed-Loop Wastewater 2-336
Coal-Fired 2-397
Coating 2-156
COD 2-313
COD/BOD 2-141
Colour 2-313
Coloured Wastewater 2-352
Condensates 2-84,2-172
Conservation 2-90
Continuous Monitoring 2-4
Control of Environmental Loads 2-179
Conversion of Willow Dust 2-361
Cooking Waste Liquor 2-303
Cooling Bath 2-50
Copper , 2-165
Copper Ores 2-164
Copper Plating 2-34
Copper Plating Bath : 2-34
Copper Recovery 2-31, 2-34, 2-50
Corrosion 2-51
Corundum 2-151
Cotton Broadwoven Fabric Mills 2-363
Cottoa Textile Processing 2-361
Counter Current Flow of Bleach Filtrates 2-214
-------
Counter-Current Rinsing 2-64, 2-67, 2-354, 2-364
Crystallization . . . , 2-16
CTM Pulping 2-289
CTMP 2-239
Cutting Oil 2-153
Cyclone Separators 2-321
Dairy Wastes 2-93
Debubbling '.- . 2-10
Degreasing . 2-28, 2-368
Delignification 2-214, 2-221, 2-280, 2-286
Deliming . 2-114, 2-127
Demineralization 2-77
Denmark 2-90
Depithed Bagasse . . . . . 2-280
Desalination 2-18, 2-395
Descaling 2-166
Desilicate 2-307
Desilication 2-295, 2-299, 2-307
Desilication of Black Liquor 2-310
Desizing Chemicals 2-350
Desizing Effluent 2-363, 2-391
Displacement Heating . 2-230
Displacement Washing . . 2rl97
Dissolved Lignin 2-214
Distillation . 2-162, 2-172, 2-368
Drag-Out Reduction . 2-34, 2-44
Drag-Out Tanks 2-40
Dragout 2-64
Drainage 3-8
-------
Drip Confinement 2-67
Drum Displacer 2-197
Dry Clean Air Emissions 2-391
Dry Cleaning Machines 2-391
Dry Forming 2-335
Dust 2-16, 2-100, 2-361
Dust Control 2-357
Dust Recovery 2-1
Dye 2-340, 2-374
Effluent Recovery 2-350, 2-363
Effluent Treatment 2-313
Effluent Water 2-329
Effluent-free 2-283
Effluent-free Paper Mill 2-335
Effluents 2-236
Electrodialysis 2-29
Electrolysis 2-40, 2-50, 2-155
Electrolytic Recovery '. 2-12, 2-31, 2-35, 2-62, 2-63
Electronic Equipment 2-31
Electroplating . 2-29, 2-34, 2-35, 2-37, 2-40, 2-41, 2-47, 2-51, 2-52, 2-56, 2-58, 2-59, 2-62, 2-63, 2-64, 2-67
Electroplating Baths 2-47
Electroplating Rinsewater 2-40, 2-62, 2-67
Electroplating Waste 2-44
Electrostatic Powder Painting 2-161
Electro-winning 2-34
End Gas Reduction 2-68
Energy 2-236
Energy Conservation 2-47, 2-106, 2-175, 2-323
Energy Reclamation < 2-108
-------
Energy Recovery 2-16, 2-168, 2-169, 2-170, 2-339, 3-2
Energy Reduction 2-44, 2-56
Energy Review 2-396
Energy Saving 2-200, 2-230, 2-239
Environmental Control 2-218
Environmental Impact Reduction 2-87
Enzymatic Bleaching 2-252
Enzymatic Pitch Control . 2-332
Enzymatic Wastepaper Upgrading 3-8
Enzyme Pretreatment 2-267
Enzyme Treatment 2-270
Enzymes 2-270, 2-332
Equipment Modification 2-16, 2-87, 2-276, 2-325, 2-378
E-stage Effluent recycling 2-265
Etchant Liquors ; . . . 2-31
Ethanol ; 2-23, 2-292
Ethylbenzeae 2-17
Eucalypt Kraft Pulp Bleaching 2-242
Eucalyptus 2-185
Evaporation 2-56, 2-329
Expert System 2-4
Explosion 2-236
Explosion Pulping 2-239
Extended Delignification 2-227, 2-230, 2-233
F.N.-CRDF Process 3-1
Fabric Dyeing 2-381
Fat Liquoring 2-122
Fat Recovery 2-83, 2-84
Fat Recycling 2-122
-------
Fats and Oils 2-87
Ferrochrome 2-170
Fenochrome Smelting 2-106
Fertilizer 2-68, 2-70, 2-71, 2-72, 2-283
Fiber Recovery 2-313
Fiberboard Mills 2-313
Fillers 2-11
Filtration • 2-90, 2-93, 2-104, 2-176, 2-326
Finishers of Textiles 2-391
Finland 2-194
Flax Pulp Mill 2-283
Flue Gas (CO£ Treatment 2-307
Fluid Bed Reactor 2-37
FIuidizedBed 2-151
Fluidked Bed Heat Treatment 2-96
Food and Kindred Products 2-93
Food Preparations 2-93
Food Processing 2-78, 2-84, 2-87, 2-93, 2-339
Food Products '. 2-87, 2-93
Food Wastes 2-87
Foodstuff 2-77, 2-81, 2-82, 2-83, 2-94
Formic Acid 2-188
Fresh Water 2-344
Gas Collection 2-22, 2-169
Gas Filtration 2-168
Germany 2-62
Gluestock Fat Transesterification 2-122
Greece 2-149
Handpicked Cotton 2-357
-------
Hard Chrome Plating 2-47
Hazardous Waste ; 2-161
Heat Recovery 2-26, 2-273, 2-321, 2-395
Heat Treatment of Metals 2-96
Heating Oil 2-394
Heavy Metals 2-248
Hemicelluloses 2-280
Hide Chilling 2-143
Hide Preservation 2-125
High-yield Pulping 2-200, 2-239
Hydrazine Hydrate 2-18
Hydrochloric Acid 2-242, 2-348
Hydrofluoric Acid 2-13
Hydrogen . . . . 2-19
Hydrogen Peroxide 2-188, 2-227, 2-236, 2-242
Hydrogen Peroxide Bleaching 2-242
Hydrogen Sulfide 2-273
Hyperfiltration Process 2-391
Ice Chilling 2-125
In-Process Measures , 2-62
Incineration 2-110, 2-123
Increased Efficiency 2-16, 2-93
Increased Productivity 2-16, 2-67, 2-93
India 2-321, 2-323, 2-346
Industrial Inorganic Chemical 2-16
Industrial Organic Chemicals 2-25
Ink 2-176
Inorganic Chemicals •. 2-16, 2-18
Insulating Panels 3-1.2
-------
Insulation 2-16
Investment Costs 2-270
Ion Exchange 2-34, 2-40, 2-41, 2-56, 2-58, 2-59, 2-62, 2-104, 2-348
Ion Exchange Backwash 2-348
Ion Exchange Regeneration 2-348
Iron and Steel 2-158
Iron Foundry 2-100
Iron Reduction
Iron Removal .
2-104
2-47
ISIC 15 2-340
ISIC 16 2-340
ISIC 31 2-83, 2-84, 2-94, 2-339
ISIC 32 2-59, 2-393
ISIC 34 2-339
ISIC 37 2-20, 2-21
ISIC 38
2-29, 2-41, 2-63, 2-151, 2-153, 2-156, 2-166
ISIC 41 2-397
ISIC 311 . 2-78
ISIC 351 2-23
ISIC 2085 2-50
ISIC 2105 - 2-104
ISIC 3111 2-74
ISIC 3113 2-82
ISIC 3118 2-77
ISIC 3121 2-81
ISIC 3211 2-354, 2-364, 2-368, 2-382
ISIC 3311 2-392
ISIC 3411 2-180, 2-181, 2-189, 2-296, 2-336, 2-337, 2-338
ISIC 3420 2-176, 2-3%
-------
ISIC 3511 2-9, 2-12, 2-13, 2-18, 2-19
ISIC 3512 . . k 2-10, 2-68, 2-70, 2-71, 2-72, 2-73
ISIC 3513 2..22
ISIC 3530 2-171, 2-172
ISIC 3540 2..17
ISIC 3560 2-173, 3-1
ISIC 3699 2.2, 3.3
ISIC 3710 2-101, 2-152, 2-170
ISIC 3720 2-155, 2-167, 2-168, 2-169
3800 2-1, 2-64, 2-165
3813 2-52, 2-53
ISIC 3819 2-154, 2-162
ISIC 3844 2-51
ISIC 4200 . . 2-395
JaPan • • • : • • • • 2-106
Jet Sprayers 2-87
Kaolin Clay 2-338
Kraft Bleaching 2-255
Kraft Paper 2-189
Kraft Pulp i _ 2-267
Kraft Pulp Bleaching 2-242, 2-248, 2-267
Kraft Pulping 2-227, 2-230, 2-270
Lactoserum . 2-94
Lactoserum Recovery „ 2-93
L6*1 2-169
Lead Oxide 2-1
Lead Plating 2-50
Leather . 2-108, 2-110, 2-114, 2-116, 2-118, 2-120, 2-122, 2-123, 2-125, 2-127, 2-129, 2-131, 2-133, 2-135,
2-137, 2-139, 2-141, 2-143, 2-145
-------
Leather By-Products 2-110
Leather Dyes 2-129
Leather Finishing 2-145
Leather Tanning 2-112, 2-150
Liftase A40 3-8
Lighting Fixtures 2-28
Lignin 2-280, 2-316
Lignin Removal Process 2-313
Lignox Process 2-245
Lime Sulphide 2-139
Liquor 2-289
Machining 2-153
Magnesium Bisulfite Pulping 2-185
Magnesium Oxide 2-120
Material Conservation 2-47, 2-93, 2-194
Material Segregation 2-361
Material Substitution 2-8, 2-28, 2-44, 2-161, 2-194, 2-374, 2-381
Mechanical Pulp 2-329
Mechanical Pulp Containing Paper 2-332
Mechanical Pulping 2-200
Mechanical Stone Grinding 2-181
Membrane Electrolysis 2-47
Membrane Plating 2-44
Mercerizing 2-364, 2-367
Metal 2-29, 2-59
Metal Complex Dyestuffs 2-129
Metal Finishing 2-41, 2-53, 2-64, 2-166
Metal Hardening 2-151, 2-152
Metal Mining 2-164
-------
Metal Products 2-67
Metal Recovery 2-64, 2-67
Metal Treating , 2-51, 2-52, 2-152
Metal-Bearing Waste 2-40, 2-44, 2-50
Metallurgical Industry •. 2-1, 2-165
Methane 2-74, 2-76, 2-108
Methanol 2-218, 2-286
Milox Process , 2-188, 2-194
Mine Tailings 2-164
Mineral Oil 2-28
Mixed Plastic Waste Recovery 3-1
Modified Continuous Cooking 2-227
Modified Pulps 2-233
Mold Filling 2-1
Molded Products 3.3
Molten Salts 2-96
Multistage Pulp Washer , 2-197
NEC 2-391
Netherlands 2-40, 2-47, 2-50, 2-56
Neutral Sulfite-anthraquinone Pulping 2-210
Neutralization 2-17
New Equipment 2-67
Newsprint Mills 2-329, 2-332
Nickel Plating 2-37, 2-40
Nickel Recovery 2-40
Nitric Acid 2-68
Nitric Oxides 2-4
Nitrogen Dioxide 2-242
Nitrophosphorous 2-71
-------
Non Chlorine Compound Bleaching 2-252
Nonfertous Metal 2-155, 2-168, 2-169
Non-toxic 2-224
Non-wood Pulping 2-313
Non-wood Pulping Effluents 2-313
NOx 2-4
NS-AQ Pulping 2-210
Nuclear Power 2-395
Nutrients • • 2-248
Nylon 2-340
Off-specification Cement 2-6
Oily Waste 2-393
Operating Costs 2-270
Ore Dust . . 2-106
Organic Chemical 2-23
Organic Growing 2-357
Organic Material 2-248
Organic Matter 2-313
Organic Painting Solvents 2-161
Organic Solvent Degreasing . . .' 2-161
Organic Vapor 2-28
ORGANOCELL Process 2-218
Organosolv Lignins . . .' 2-218, 2-221, 2-286
Organosolv Pulping 2-188, 2-210, 2-218, 2-221, 2-286
Oxidation 2-18
Oxidative Extraction 2-259
OxO Process 2-255
Oxygen • 2-242
Oxygen Bleaching 2-224, 2-242
-------
Oxygen Delignification 2-227, 2-255, 2-259, 2-270
Oxygen Prebleaching , 2-255
Oxygen-alkali Cooking 2-224
Ozone 2-242
P8"14 2-20, 2-26, 2-156
Paint Waste 2-158
Painting 2-28, 2-158
Paper 2-189, 2-236, 2-271, 2-296, 2-336, 2-337, 2-338, 2-339, 2-396
Paper and Board Mills . 2-313
Paper and Pulp 2-326
Paper De-Inking 3.5
Paper Mill 2-329, 3-12
Paper Mill Effluent 2-335
Paper Production 2-200, 2-335, 3-8
Papricycle Process 2-265
Particulate Emissions . 2-397
Pelletized Ore , 2-106
Peracetic Acid 2-242
Perchloroethylene 2-391
Peroxide Bleaching 2-224, 2-245
Peroxide Steep Bleaching 2-185
Peroxyformic Acid Method 2-188
Personnel Training 2-20
Petroleum 2-171
Petroleum Refining 2-172
Phosphorous 2-9
Pickle Liquor 2-104, 2-173
Pickling 2-101, 2-155, 2-165
Pigments 2-382
-------
Pitch Reduction 2'332
Plastic 2-20' 3-J
Plating and Polishing 2~67
Plating Baths 2"56
Plating Wastes 2'50
Pollution Control 2'397
Poly Vinyl Alcohol (PVA) 2'363
Polyactylates (PAA) 2'363
Polyurethane 2'22
Portland Cement 2~4
Portland Cement Manufacture 2-4
Potassium 2'283
Potassium-based Sulphite Pulping 2-283
Potato 2'78
Potato Starch Manufacturing 2"80
Powder Process 2'28
Precipitation 2-U» 2-120, 2-150
Prehydrolysate Liquor -. • 2-319
Pressure Atomized Electrostatic Paint Spray 2-158
Pressure Groundwood 2-200
Pretannage 2"135
Printing 2'176
Printing Ink 2'175
Process Alternatives 2-108> ^l25' 2'143
Process Change 2'26, 2-154, 2-190, 2-272, 2-273
Process Control 2-6' z~90
Process Efficiency 2-4, 2-93
Process Modification 2-25, 2-44, 2-67, 2-87, 2-96, 2-98, 2-147, 2-158, 2-161, 2-192, 2-194, 3-5
Process Redesign '. - 2-lfi> 2-164« 2-276> 2'372
-------
Process Simulation 2-329
Process Substitution 2-289
Process Waste Recovery 2-384
Process Water Recovery 2-388
Product Substitution 2-357
Providence Method 2-64
Pulp 2-189, 2-2%, 2-321, 2-337, 2-338
Pulp and Paper 2-180, 2-181, 2-190, 2-272, 2-273, 2-277
Pulp and Paper Mill Effluents 2-313
Pulp and Paper Mills 2-276
Pulp Bleaching 2-185, 2-252, 2-259, 2-262, 2-265, 2-270
Pulp Mill Effluent . 2-200, 2-230, 2-283, 2-299
Pulp Mill Liquid Waste 2-310
Pulp Mill Solid Waste 2-310
Pulp Mills 1 2-192, 2-194
Pulp Plant Effluent 2-218, 2-224, 2-236, 2-295
Pulp Production 2-203
Pulp Washing 2-197, 2-329
Pulping 2-218
Pulping Effluent 2-188, 2-210, 2-319
Pulping Liquor 2-316
Pulping Process 2-280
Pulping Waste Liquor 2-303
Pulping Waste Water 2-197
Pumps and Pumping Equipment 2-67
PUNEC Pulping Process 2-280
Purification 2-17
PVA (Poly Vinyl Alcohol) Recovery 2-363
Pyrolysis 3-2
-------
QSL Process 2'169
Quarry Waste 3~3
Radio Frequency (RF) Dryers 2'175
Raw Material Substitution 2'18' 2'147> 2'175
RDH - - 2-23°
Reaction Verification 2"10
Reclamation 2-40,2-50,2-90
Recovery . 2-18, 2-29, 2-35, 2-37, 2-59, 2-73, 2-90, 2-101, 2-149, 2-151, 2-295, 2-299, 2-310, 2-326, 2-340,
2-342, 2-367, 2-393
Recovery and Reuse
Recovery Effluent • • • 2"319
Recycle 2'26' 2^
•j 955
Recycled Oxygen Process •'••"•'
Recycled Paper Panels 3'12
Recycling . . 2-2, 2-20, 2-21, 2-29, 2-52, 2-53, 2-80, 2-101, 2-139, 2-151, 2-153, 2-155, 2-176, 2-190, 2-296,
2-326,2-337,2-340,2-348
Recycling of Paper/Cement Sack Paper 3"15
Recycling of Sugarcane Bagasse 2"292
Reducing Agents • 2'381
Reduction Furnace 2'169
Refrigerant 2'16
Refrigeration and Heating Equipment 2'16
Refrigeration of Solvents 2'391
Refrigeration Waters 2"16
Regeneration
Regeneration Cell ; 2"50
Residential Heating 2"394
t* A *
Resin Adsorption
Reuse 2-37, 2-149, 2-342, 2-346, 2-348, 2-359, 2-361, 2-367, 2-376
fy QQ
Reverse Osmosis - ^
-------
Reversed Osmosis 2-329
Rice Straw 2-299
Rinsate 2-67
Rinse Procedures 2-364
Rinsewater 2-29, 2-35, 2-41, 2-90, 2-101, 2-384, 2-388
Rinsewater Reuse 2-90
Road Construction 2-283
Rotalyt-Alutop 2-51
Salt Removal 2-118
Salt Use Reduction 2-125
Sand 2-100
Sand Filter 2-67
Sanitary Papers 3-15
Scrubber Effluent 2-272, 2-273
Scrubber Sludge 2-100
Sewage Effluent Recycling 2-386
Sewage Effluent Reuse . 2-386
Sewage Effluent Water 2-386
Sewage Water 2-386
SIC 22 2-342, 2-376, 2-378
SIC 26 2-190, 2-272, 2-273, 2-277
SIC 28 2-11
SIC 34 2-35
SIC 36 2-26
SIC 1021 2-164
SIC 1094 2-164
SIC 2063 2-76
SIC 2200 2-384, 2-386, 2-388, 2-391
SIC 2202 2-90
-------
SIC 2211 2-361, 2-363, 2-372
SIC 2231 2-350
SIC 2269 2-391
SIC 2299 2-321, 2-323, 2-325, 2-344, 2-346, 2-348, 2-354, 2-359, 2-367, 2-370, 2-374
SIC 2611 2-271
SIC 2621 2-326
SIC 2700 • • 2-175
SIC 2869 '. . . : 2-25
SIC 2873 2-72
SIC 3111 2-147, 2-150
SIC 3241 2-4
SIC 3313 - 2-106
SIC 3322 2-100
SIC 3433 2-394
SIC 3471 . . . 2-34, 2-37, 2-40, 2-44, 2-47, 2-56, 2-62
SIC 3529 3-2
SIC 3648 2-28
SIC 3672 ••• 2-31
SIC 7216 2-391
Silica 2-11, 2-296
Silica Content 2-307
Silica Removal 2-307
Silver Recoveiy 2-62
Simulation 2-270
Sludgo 2-9, 2-67, 2-100, 2-339, 2-346
Sludge Handling 2-313
Sludge Pump 2-100
Sludge Reduction 2-40, 2-44, 2-56
Slurry 2-164
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Slurry of Residual Used Cement 3-15
Smelting 2-169
Soda Pulping 2-295
Sodium 2-248
Sodium Chlorate 2-16
Sodium Hydrogencarbonate 2-127
Sodium Sulfide 2-381
Solid Waste Recovery 2-11, 2-13, 2-31, 2-296
Solvent 2-23, 2-145, 2-162, 2-374
Solvent Emissions 2-175
Solvent Extraction 2-25
Solvent Recovery 2-368, 2-396
Solvent-Based Ink 2-175
Solvents 2-218, 2-221, 2-280
Source Reduction 2-16, 2-67, 2-87, 2-112, 2-118, 2-137, 2-147
South Africa 2-363
SOx 2-4
Spent Liquor 2-307
Spent Liquors 2-295
Spent Tanning Liquor 2-147
Spill Control 2-90
Stabilization 2-141
Starch 2-78, 2-363
Static Rinsing 2-58
Steam 2-265
Steam Explosion Pulping 2-236
Steel 2-101
Steel Galvanizing 2-98
Steel Strip 2-104
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Strength Properties 2-227
Substitution 2-372
Sugar Beet Processing Effluent 2-76
Sugar Products 2-76
Sulfate Pulping 2-233
Sulfite Impregnation 2-239
Sulfite Pulping with Methanol 2-214
Sulfonation 2-206
Sulfur 2-190
Sulfur Dioxide Emissions 2-276
Sulfur Oxides 2-4
Sulphate Process 2-321
Sulphate Pulp Mill 2-179
Sulphite Pulping 2-283
Sulphur Dioxide 2-242
Sulphur Reduction 2-194
Sulphur-free 2-224
Super Batch Cooking 2-233
Super Pressure Groundwood 2-200
Synthetic Fiber Mill 2-325
Tail Gases 2-167
Tanning . 2-108, 2-110, 2-114, 2-116, 2-118, 2-120, 2-122, 2-123, 2-125, 2-127, 2-129, 2-131, 2-133, 2-135,
2-137, 2-139, 2-141, 2-143, 2-145, 2-147
Textile Dye Reduction 2-391
TextileDyeing <. 2-374
TextileDyes ' 2-391
Textile Industry 2-321, 2-323, 2-344, 2-346, 2-348
Textile MiU Production 2-384, 2-388
Textile Mill Products 2-342, 2-350, 2-363, 2-376, 2-378, 2-384, 2-388, 2-391
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., „.„ 2-363, 2-386
Textile Mills
Textile Solid Wastes • > ' 2~346
Textiles 2-151, 2-325, 2-340, 2-352, 2-354, 2-364, 2-367, 2-368, 2-370, 2-382
Thermal Waste 2"321
2-200
Thermomechanical Pulp
Tires 3'2
Titanium
Titanium Salt 2"133
TMP Process 2"203
Toxic Vapors •
9-^44
Treated Wastewater z J4H
Trichloroethylene • 2"28
Ultra High Yield 2"236
Ultrafiltration . 2-50> 2'139> 2'153> 2'329' 2'393
Ultrafiltration Process 2-350, 2-363
Ultraviolet (UV) Curable Polymers 2-145
Unhairing • 2"137
United Kingdom 2-4, 2-31, 2-44, 2-76, 2-100, 2-147, 2-175
Uranium Ores • • 2"164
Urea • • • 2"71
Vacuum System • 2"87
Vapor Phase Pulping Process • • "2-236
Vegetable Tanning • 2-116
Volume Reduction 2'16> 2~61' 2'164
Volume Reduction Thin-Layer (TL) Process . 2-164
Washing • • 2"197
Waste Disposal 2~no
Waste Glass 3'3
Waste Heat 2-395
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