5404
001^77103
Industiy in the United States purchases about 27 quads- annually,
ap Dvoxlmately --0/< of rot^l national energy usage (sec Table "< , Col. 6 • ..
This energy is used for chcndcal process i ng, iv-ifainj. steam, drying,
space cooling, aud heating, proces ; ctv-'in1 boating, and rascol 1 aneox:s
other purposes.
In Ecmy industrial sectors energy consuTptri 01, GJU be reduced : '.g-
nificantly by bet.te:' "housekeeping" (i.e., shutting orf standby furnaces,
bett.-r theimost it control, ellminat ion of °,Leani and heat "'oaks, ei:c.)
and j/,r?,rit:er r'n:i"naris ra oorimi/arion of eneryv u'ja^c. In addritioa,
hoi.7?vors "indus rv can be e::pe;-ted to ;u; roduco ru:'W iuci;.:serial p':;n.i-ices
or processes cither to conserv" --nerpy rr •..1 taiie ;:c'vapta:je ol: a ;,'ore
readily availa'.-. Le or less o->stlv fuel, Such changes in indnstrlaJ
practices iray -ejniit in ch i.i^es in air, water o. solid waste discharge;-;,
The E-'A is interested in identjryjng the j-o.i ] ctica loads uf snch ^cw
energy-conserving industrial pracc.ices o-~ [recesses and nn eef'-riiiiiiing
where -:ddi Lion-'il research, development, or de-ncnslrr tion is ni'odcd co
characterize and control the efflaent streams.
In the first phase of thLS study ve identified manuiacruring in-
dustry sectors that have a potential for change, emphasizing those
changes which have an environment'a! /energy impact. We focused on identi-
fying changes ?'n the primary production processes which have clearly
defined pollution consequences. In selecting those to be included in
this study, ve have ronsicU red the needs ana liiiiitni ions of the F.PA
as d i scus,-,ed u -n c completely in the Ji'.dusLry i'rjci'ity R-po.L. Speci f i cal ly,
eneiv', ;0;:,-;etv :!ii'i has been lei ini'd n]..a(0% 10 ini'i'o.i.j, in •;(!.•' i ti on
to piHH'-S'-; chai.;;.'i-; cov,ojvat.i v of t :x r^y >r energy lorn (.i-ns, oil, co;-.i)
: 1 5
i. ijuad 10
-------
-------
AVAILABILITY OF REPORTS FROM EPA PROJECT ON ENVIRONMENTAL
ASSESSMENT OF ENERGY-CONSERVING INDUSTRIAL PROCESS OPTIONS
Copies of reports from a major industrial environmental assessment
are available upon request for specific volumes from the address given
at the lower right hand corner of this sheet.
The full title of this EPA study, individual volume titles, and
report numbers are as follows:
"Environmental Considerations of Selected Energy Conserving Manufacturing
Process Options" - Interagency Energy-Environment Research and Development
Report, U.S. Environmental Protection Agency, December 1976:
Volume I. Industry Summary Report. EPA-600/7-76-034a.
Volume II. Industry Priority Report, EPA-600/7-76-034b.
Volume HI. Iron and Steel Industry Report. EPA-600/7-76-034c.
Volume IV. Petroleum Refining Industry Report. EPA-600/7-76-034d.
Volume V. Pulp and Paper Industry Report. EPA-600/7-76-034e.
t
Volume VI. Olefins Industry Report. EPA-600/7-76-034f.
Volume VII. Ammonia Industry Report. EPA-600/7-76-034g.
Volume VIII. Alumina/Aluminum Industry Report. EPA-600/7-76-034h.
Volume IX. Textile Industry Report. EPA-600/7-76-0341.
Volume X. Cement Industry Report. EPA-600/7-76-034J.
Volume XI. Glass Industry Report. EPA-600/7-76-034k.
Volume XII. Chlor-Alkali Industry Report. EPA-600/7-76-0341.
Volume XIII. Elemental Phosphorus and Phosphoric Acid Industry
Report. EPA-600/7-76-034m.
Volume XIV. Primary Copper Industry. EPA-600/7-76-034n.
Volume XV. Fertilizer Industry Report. EAP-600/7-76-034o.
Copies should also be available for sale from the Superintendent of
Documents, Government Printing Office and from the National Technical
Information Service.
Power Technology and Conservation Branch
Energy Systems Environmental Control Division
Industrial Environmental Research Laboratory
U. S. Environmental Protection Agency
Cincinnati, Ohio 45268
(513) 684-4318 FTS or commercial
-------
-------
TABLE .1
DISTRIBUTION OF ENERGY CONSUMPTION BY SECTOR (1971)
Purchased Fuels Purchased Fuels
Plus Electricity" Plus Electricity
Valued on Thermal Valued on Fossil
Purchased Fuels Basis Fuel Basis"""'
Sector
Industrial
-Manufacturing
-Non-Manufacturing
Total Industrial
Household /Commercial
Transportation
Electrical Generation
Total
12
10 Btu %
14,329
5,965
20,294
14,281
16,971
17,443
68,989T
20.8
8.6
29.4
20.7
24.6
25.3
100.0
1012Rtu
16,085
6,538
22,623
17,441
16,989
_
57,053
%
27.9
11.7
39.6
30.6
29.8
-
100.0
10l2Btu
19.732
7,728
27.460
24,006
17,026
-
68,492f
%
28.8
11.3 '
40.1
35.0
24.9
-
100.0
Purchased electricity valued at its thermal equivalence of 3,412 Btu/kWhand i
allocated to consuming sectors. i
Purchased electricity valued at an approximate fossil fuel equivalence |
of 10,500 Btu/kWh and allocated to consuming sectors. '
t
Totals would be equivalent if all electric energy were generated from
fossil fuels at a rate of 10,500 Btu/kWh.
Source: FEA, Project Independence, Blueprint, Vol. 3, November 1974, and
Arthur D. Little, Inc. estimates.
Arthur H I Ittk1 I IK
-------
by a process or feedstock change. Natural gas has been considered as
having the highest energy form value followed in descending order by
oil, electric power, and coal. Thus, a switch from gas to electric
power would be considered energy conservation because electric power
could be generated from coal, existing in abundant reserves in the
United States in comparison to natural gas. Moreover, pollution control
methods re; alt ing in energy conservation have also been included within
the scope cf this study. Finally, emphasis has been placed on process
changes with near-term rather than long-term potential within the 15-year
span of tine of this study.
Industries were eliminated from further consideration within this
assignment if the only changes that could be envisioned were:
* energy conservation as a result of better policing or "housekeeping,"
o better waste heat utilization,
o fuel switching in steam raising,
o power generation or production of synthetic fuels.
After discussions with the EPA Project Officer and his advisors, 13
industry sectors were selected for inclusion in this study as shown in
Table 2. These 13 industries or industry segments account for about
two-thirds of the energy used in the manufacturing indsutries (Table 2).
In consultations with the EPA Project Officer and his advisors from EPA,
FEA, NBS, and other agencies, several hundred manufacturing processes
or process options were screened and some 80 were selected for in-depth
analysis (see Table 3). The results of the study are summarized in fifteen
(15) reports prepared for EPA (an Industry Priority Report , 13 Industry Assess
ment Reports, and an overall Summary Report). Highlights of this study are
given below.
-3-
ArtluirD Mule, Inc.
-------
SUMMARY OF 1971 FNCRGY PIJRCHASFO TU SFI.FCTFD INDUSTRY SKCTORS
Indus try Sec tor
1. Blast furnaces and steel mills
2. Petroleum refining
3. Paper and allied products
4. 01of ins
5. Ammonia
6. Aluminum
7. Textiles
8. Cement
-9. Glass
10. Alkalies and chlorine
11. Phosphorus and phosphoric
acid production
12. Primary copper
13. Fertilizers (excluding ammonia)
o15
3
2
1
0
0
0
0
0
0
0
u
0
0
Btu/Yr
/(oO)'
'9G(2)
.59
.984(3)
.63(4)
.59
.54
.52
.31
.24
.12(5)
.081
.078
SJC Code
In Which
Industry Found
33 ir
2911
-26
2818
287
3334
22
3241
3211, 3221, 3229
2812
2819
3331
287
Estimate for 1967 reported by FFA Project Independence Blueprint, p. 6-2,
(2)
(3)
(4)
(5)
USGPO, November 1974.
Includes captive consumption of energy from process byproducts (FEA Project
Independence Blueprint)
Olefins only, includes energy of feedstocks: ADL estimates
Ammonia feeds toek energy included: ADL estimates
ADL estimates
Source: 1972 Census of Manufactures, FFA Project Independence Blueprint,
USGPO, November 1974, and ADL estimates.
Arthur I) Little, Iiic
-------
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In orcior to properly assess the in.pa< t of these processes, an
analysis was made of both the currently practiced technology and the
alternative technology that may be implemented in new facilities or
rebuilt plants within a time frame of about the next 15 years. Where
processes could be retrofited we attempted to identify such situations.
To the extent possible we attempted to si art with similar raw materials
to make similar end products. For both laseline and new technology,
three main factors entered into the assessment:
e identification of the pollutants,
a development of capital and operat: ng costs for both production
and pollution control aspects, am
0 determination of energy vised in baseline and alternative technology
for both production and pollution control.
Judgments were then made about economic viability and likelihood of
implementation of the alternative process. Finally researc-h areas were
identified.
Since most processes in the heavy industrial chemicals and metal
industries take anywhere from five to tvTenty years from initial inception
to commercialization, it is clear that few if any of the processes being
considered for implementation have been developed in the United States
as a result of a concern with high cost energy. "Energy-conserving
technology" when it is being applied now in the United States has been
developed largely abroad, mainly in Europe or Japan. Examples that can
be cited are collection of carbon monoxide gas from basic oxygen furnaces
(developments by Japanese and French companies) , suspension preheaters
in the cement industry (German and Japanese developments) , and flash
smelting in the copper industry (Finnish development).
Sjyn Ajrn_jra INDUSTIU AL JJ_^Ci:SS _
In examining the 80 processes considered lie re in depth a wide di-
versity of process changes were considered. Scpe of the process changes
could have upstream or downstream impacts. For example substitution of
-7- AithurI)I.ittic>.lnc
-------
electric furnaces for gas-fired furnaces woul-1 generally lessen process
pollution problems but increase emissions at the electric power generating
site. A number of processes weiv identified as having potentially smaller
pollution control costs while at the s.ire '. ii.,- reducing energy requirements.
Sorie examples are shown in Tables 4A-E. Table 4F gives an overall picture
of the relationship between energy conservation and pollution control costs
for all the new process technologies studied. In addition some problems/
impacts extend across several industries and are discussed below.
1. Availa ility of Petroleum-Based Feedstocks and Coal Gasification
Major concerns faced in the United States today are:
» The capital availability problem
o Assi ring continuing supplies of a given energy form such as
natural gas for fuel 01 feedstock.
For example in the glass industry natural gas is in short supply,
ani many of the glass companies have been looking at coal gasification
processes. Sucli coal gasification processes tend to be capital intensive
and are thus not particularly interesting from an investment/economic view-
point. Moreover a gasified coal would effectively increase the price
of fuel to about $3 per million Btu compared to the regulated prices
of about $.60 to $1.00 per million Btu that were being paid by industry
in early 1975. Similarly increased concern is being expressed about
the use of natural gas in the manufacture of ammonia and attention is
being given to making ammonia from heavier feedstocks or from coal. As
another example, injection of natural gas into blast furnaces is no
longer being actively considered as a viable option for new facilities
and increased consideration is being given to injection of liquid fuels,
possibly slurried with coal, or direct coal (steam coal) injection.
Considering the price of regulated gas at below $1 per million Btu, all
such coal based options tend to be more expensive, but are being actively
censidered and even implemented by industry because of concerns with
natui.il gas availability. Thus in industry WL expect more oil and coal
use in place of natural gas as a fuel as well as feedstock substitute.
-8-
Arthur I) Little-, Inc.
-------
EXAMPLE OF ENERGY CONSERVING PROCESS TECHNOLOGY
HAVING POTENTIALLY SMALLER POLLUTION CONTROL COSTS
» Aluminum
— Alcoa Chloride*
- Hall-Heroult/Refraclory Metal Cathodes*
— Clay Chlonnation vvith Alcoa Chloride*
• Coppet (. 85% Sulfur Recovery)
— Noiancla Smelting Process*
— Flash Smelting"
» Copper
- She, Flotation"'
— Us" of OxyrjC'iT*
*Btu Saving as Well :>s Energy Form Saving
Arthur HI ittlc-ln
-------
TABLE_4B
EXAMPLE OF ENERGY CONSERVING PROCESS TECHNOLOGY
HAVING POTENTIALLY SMALLER POLLUTION CONTROL COSTS
« Cement
— Susponsion Proheatei
— Flash Calciner*
9 Glass
— Prehonting/Batch Arjt lomeration *
— Coal
*Btu Savincj as Well as Enorcj1' Form Saving
-10-
ArthurDl.itiluInc
-------
TABLE 4C
EXAMPLE OF ENERGY CONSERVING PROCESS TECHNOLOGY
I-AVING POTENTIALLY SMALLER POLLUTION CONTROL COSTS
» Chioralkali: Dimensionally Stable Anodes
— Standard Membrane'
— Stabilized Asbestos*
— Microporons Mombiane*
— Ion Exchange Membrane*
® Iron and Steel
- Collection of CO Gr.scs from Basic Oxygen Process*
— External Dr,suifuri/at;on of Blast Furnace Pig Iron'
— Direct Redurtion'
— Diy Qucncl'iiif! of Cokev
*Btu S
-------
TABLE 4D
EXAMPLE OF ENERGY CONSERVING PROCESS TECHNOLOGY
HAVING POTENTIALLY SMALLER POLLUTION CONTROL COSTS
• Phosphoric Acirl (Detergent Grade)
— Cleanup of Wet Acid by Neutralization/
Precipitation *
— Solvent Extraction*
• Phosphoric Acid via Strong Acid Process *
* Pulp and Paper
— Rapson Effluent Ftce Process*
— Alkaline — Oxygen Process"
*Btu Saving as Well as Energy Form Saving
-12-
Arthur!) Little,In
-------
EXAMPLE OF ENERGY CONSERVING PROCESS TECHNOLOGY
HAVING POTENTIALLY SMALLER POLLUTION CONTROL COSTS
« Textiles — Knit Fabrics
— Advancer! Aqueous T -occss*
— Solvent Processing*
o Textile- Woven
— Advanced Aqueous*
° Nitric Acid (NOX Control
— Molecular Sieve"
— Giancl Paroisse*
-CDL/Vitok"'
- Masar*
* Btu Saving as Well as Energy Foini Saviny
-13-
Aithui'Dl ittli-
-------
TABLE 4F
DISTRIBUTION OF NEW PROCESS TECHNOLOGIES
Energy
Conservation
Potential
More Than
rriv
D/o
Savings
No
Change
Increased
Energy
Use
12
2
3
6
2
0
24
3
2
Increase1 No Cha.igo Mote Than
In Control 5%
Costs Savings
Savings in Pollution Conttol Costs
-14-
ArthurD! itilc.ln
-------
2j. _ NO /SO ^missions
a. Coal use: With increased use of coal, one can expect higher NO
y^
emissions from reverberatory furnaces in the copper industry, cement kilns, etc,
In addition sulfur emissions can be expected to increase because of sul-
fur found in coal but not in pipeline quality natural gas. Generally, the
use of coal increases NO emissions compared to firing with natural gas
2C
or fossil fuels, mainly because 1) coal generally requires larger amounts
of excess air to achieve complete combustion and 2) nitrogenous compounds
in coal are apparently easily oxidized to NO .
X
b. Oxygen Use: Another area in which NO emissions are of conceri is
. ^_^-_ -^
in the increased use of oxygen which has received considerable attenticn,
Generally oxygen use tends to conserve fuel use because flame temperati res
are somewhat raised which increases the efficiency of the furnace. Foi
example, when oxygen was introduced into the open-hearth steclmaking
furnaces the throughput rates increase by as much as 50%, Such use of
oxygen is now being considered in the iron and steel industry, in the
glass industry and in nearly all industries now u.^ing fossil fuels iu
furnaces. The increase in the flame temperature would tend to raise N0_r
levels. Holding NO levels constant would demand better control of
the air fuel combustion ratios in bringing them closer to stoichiometric .
Thus both coal use and oxygen use can be expected to increase NO
X
emissions .
JL_ Preheating
With energy costs escalating, increased emphasis is being given
to preheating. Preheating can be accomplished in a variety of vessels
or types of vessels such as static beds, moving beds, fluid bed devices,
gas liquid heat exchangers, gas-gas heat exchangers, etc. All of these
processes or procedures have the commonality of extracting waste heat
from product streams or providing process heat at lower temperatures.
Major environment a] problems with solid preheating are dusting, incomplete
coaihu.s ticn 01 vo];. tiles, and potential for fugitive emission;-,.
n,'
-------
Solid preheat ing generally has the environmental advantage of re-
ducing NO emissions per ton of product because less energy is being
x
supplied by high temperature combustion. In addition capital investments
for prehe.aters tend to be modest in comparison with the total plant.
Since many preheaters can be retrofitted to existing facilities the impact
on energy use can be felt in a shorter t-'rr.e frame than other options
requiring completely new plant facilities entailing high investments.
Thus increased NO emissions from coal and oxygen use ran be somewhat
ameliorated by application of preheaters
In conclusion major process changes promoted by a desire to conserve
energy that are being considered involve increased use of coal due to
shortage of natural gas and increased ust of oxygen and use of preheaters
for energy conservation.
Overall because of concerns on capital availability and risks en-
tailed in application of new process technology, we expect the pace of
process change to be slower than in the 1950's and 1960's, with industry
making every attempt to get as much production as possible out of existing
plants before starting construction of new facilities.
-16-
Arthurl)l.iltk',lnc.
-------
ENV T.RONMENTAT. FIND INGS
In the course of this studv Involving thirteen b£istc Industries, a
number of energy conserving processes were identified as having potentially
smaller pollution problems than currently practiced technology." Examples
include such options as the Rapson effluent, free process in pulp manufacture
and the Alcoa aluminum process. However, in the majority of options examined
the types of pollutants will not change significantly because the energy con-
serving mar ^facturing processes involved over the next 10 to 15 years will
utilize essentially the same raw materials to produce essentially the. same
products. 'loroover, the quantities of pollutants emitted from these processes
and the ene-gy source", used will generally increase. More stringent regula-
tions on em .ssions will increase simultaneously the amounts of concentrated
pollutants ;hat must be prevented from entering the environment and the amounts
of energy aid resources used in removing pollutants. In particular, the
replacement of natural gas and oil with coal will mean a concomitant increase
in:
s The amounts of gaseous pollutants such as sulfur oxides and
nitrogen oxides, and
o the amounts of sludges containing toxic and hazardous
substances such as heavy metals corning frotn the energy
supply sources.
Furthermore, in switching from gas to oil to coal increased environmental
impact can be expected in obtaining the fuel, for example, strip mining,
tailings disposal and in disposal of residuals as sludges, etc. In short,
the single most important cause of increased environnenta] impact will cone
from changing fuel forms/feedstocks and not as a result of introducing new,
anergy conserving processes.
ENVIRONMENTAL RESEARCH AREAS
With a few exceptions, pollution control technology is available today
to meet probable emission standards over the next five to ten years. (Exceptions
such as for fine particulate control are noted below.)
*Sce Tablo A.
-17-
ArthuiT)! ittlc.lnc
-------
However, research and development efforts are needed to establish more
cost effective pollution control technologies especially in reducing capital
investment requirements and ope? at in;,; costs. In particular, it is necessary
to establish the effectiveness of pollution control technologies in each industry
sector by demonstration projects in order to provide a firm basis for estab-
lishing practicable and achievable emission standards. These research and
development needs must focus on demonstrating:
a effectiveness of removal of designated pollutants,
o cross-media effects, and
a health and ecological impact of pollutants where removal
may be either beyond the capabilities of existing technologie 3
or unacceptable dn socio-economic terms.
Consequently, establishing the technical and economic capabilities of
pollution control systems through research and development must be done in
consonance with the ecological and health aspects of pollution emissions.
If maximum utilization of R&D funds are to be made, it is apparent tha^
priorities of allocation must be established on a broader base than merely
improving the capabilities of technology, i.e., consideration must be given
to the need for reducing emissions from an ecological and health viewpoint,
the cross-media impacts and the socio-economic effects,
Specific areas for research and development efforts in the particular
industries of major concern are as follows.
1. Air Pollution Control Technology
With regard to air emissions in the new process technologies investigated,
we have identified the following to be deserving of R&D attention:
* Improving fine particulate removal technology. This would
include those participates resulting from metallic smokes and
sublimed substances such as mercury, arsenic, zinc, etc. For
example tins problem can be found in glass furnaces where compounds
are sublimed and volatilized. Similarly direct firing of coal or
hot gas generation from coal for use in furnaces or kilns can involve
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volatilizing of the trar< fnctalr; foiiad in coal. Other industry
sectors examined that face thcf;e kinut-. of fine particulnto removal
problems are aluminur., ammonia, cement, copper, f IT t i 1 i x.or , iron
and steel, petroleum refining, phosphorus, and pulp and paper.
Collection or contro 1__o_f _f uj^i_tjA'_e_ _erri ssions from process
equipment. The collection and removal of emissions from equip-
ment at points other than associated with process requirements
(so-called fugitive emissions) such as from high temperature
processes like preheaters for cenent kilns or external desulfuriza-
tion of blast furnace hot metal can be expected to become of
increasing importance. Besides the cement and iron and steel
industries, fugitive emission >roblems will be found in the
aluminum, ammonia, copper and fertilizer industries.
Better definition_of the ^environmental, hea.l th, and ecol ogical
imp n c t s o f g. a s e o u s e mi s s i on s (such. as SO , NO , CO , IIF _ CA,^,
Process in steelmaking, NO emissions from nitric acid plants,
and ammonia emissions from aeration of scrubbing liquors found
in the fertilizer mixing industry, metallic smokes from molten
metal transfers and volatile impurities in iron and steel and
copper are examples. Other new technologies facing these
type of emission problems are found in the following industry
sectors; aluminum, ammonia, cement, chlor-alkali, glass,
petroleum refining, and pulp and paper industries.
Better definition of the environmental , ecological , _an_d health
impacts of compounds that have high smog forming characteristics
and/or have toxic effects. Examples can be found in the use of
volatile organic solvents in some new textile technology (solvent
processing), or emissions from coke ovens. The major industries
where this is a problem is aluminum, iron and steel, olefins,
petroleum refining, and textiles.
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e Improvements in odor control. Examples whore this has been a
problem is the sulCur emissions (c.;;., Il^S, mcrcaptans, etc.) as
found in petroleum refining and pulp and paper.
0 Improved ins trumentat icn _ for rapid nrinitorjmg and recording of
airborne emissions. The major needs for such instrumentation are
(1) to provide a rapid indication of the effectiveness of control
and (2) provide records for rejul^tory agencies. Industries where
the improved instrumentation is especially needed are alumina,
copper, glass, iron and steel and pulp and paper.
2 . EfLtJLLJ ollution Control Technology
With r< gard to water pollution control in new technology investigated
in this stui y, we have identified the following as deserving consideration
for additional research and development.
Better de f_i nit ion of th e_ _ env ir onn en t a 1 , h e -. ' J^th_^_£nd_ ecological
biolor,Jcal_ hal f-1 ivy^ or tox_ic e_f_fect_s_. I'.xarnples in the major
industries include wet scrubbing liquors in the aluminum and
petroleum refining industries. Another example is hydrometallurglcal
technology involving dissolved trace metals such as leaching copper
ores/concentrates. Other major industries where this is a
problem is ammonia, iron and steel, phosphorus, and pulp and
paper.
o Improvements in suspended solids removal from treated wastewaters.
This is a problem found particularly in the pulp and paper
industry (biological floes), the "phossy-water" problem found in
the manufacture of phosphoric acid, and the slimes generated in
mining phosphate rock.
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9 Ident i fic a L ion o f jrv f ray t c -ry_ orj;an i_c_ compounds and improvement
^J_'L(zEL(2X2J -J-J-l^100-^0*' M?s • Such problems can be potent j n 1 Ly found
in textiles, manufacture of phosphoric acid, or extraction of
alumina where such organic compounds may be generated as a result
of solvents used or as a result of high temperature synthesis
(e.g. Alcoa process),
e Improved instrumentation for rapid monitoring and recording
of waterborne pollutants. Examples are found in the iron and
steel industr> where temporary upsets or transient conditions
may cause large amounts of pollutants to enter the control sy items,
e.g., such as cyanide emissions from external desulfurization or
zinc or other tramp elements from electric arc furnaces.
3 • Solid Waste Disposal
As the quantities of pollutants emitted to the air and water environment
are decreased, there is usually a concomitant increase in solid waste or
sludges. These must either be destroyed, or disposed of in a manner which
presents further dJssemination into the environment. The following areas
have been identified as deserving R&D attention.
o Technica 1 d cmons t r a t i cm o f a d e a u a t a land_f i 1 _1 di sposal techniques .
Aluminum (extraction of alumina which can produce 1 to 2 tens
of dry solids per ton of alumina), cement (leachable alkali
metal dusts), iron and steel (basic oxygen furnace and electric
furnace dusts containing tramp elements ]ike lead and zinc),
petroleum refining (disposal of sulfur and/or its compounds from
desulfurizing operations or stack gas scrubbing) and phosphoric
acid processes involving disposal of calcium sulfate or calcium
chloride.
9 Demonstration of thermal destruction technologies. The thermal
destruction of residues and tars from some of the new olefin
technology may be the best overall method of handling such wastes.
Other examples can be found in the aluminum and petroleum refining
sectors.
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Addi t ional r c s ca r cV> into
and research into It rvi i m.ethodo 1 :rj,i c-.s_ lor__cmUj"o_UJ_ni;_ tlie__d_i s
of solid wastes. Ex. imp 1 es can be ritid In the manufacture of
ammonia from coal involving disposal of mine wastes and coal
residues from gasifying facilities or the disposal of kaolin
clay wastes in the manufacture of alumina via acid Iciichlng processes,
Other examples can be found in the cement, copper, fertilizers,
glass, iron and steel., olcfins, petroleum refining and manufacture
of phosphoric acid.
ENV IRO_NMENTAL^ REG : AP ITULAT ION
Thus, in each case, the direction o research programs should be viewed
with the objective of attaining the maxi mm effectiveness for removal or
controlling pollutants at the minimum economic penalty, since it is rarely
possible to remove or control pollutants to present and anticipated standards
without entailing at least some costs. Consequently, research programs must
be examined within the f raniework of cost/benefits to the environment, to
human health and to the economy.
Table 5 provides our perception of those areas in each industry examined
where the first and second level priorities for research, deve1 opment and
demonstration should be placed. Tables 6A-C show summaries of these results.
Examination of this table Indicates to us that the first two industries into
which the most effort should be placed are petroleum refining, iron and
steel, pulp and paper and aluminum. A second tier includes all of the re-
maining industries except chlor-alkali and fertilizer mixing plants which
are judged to not have significant problems requiring further RD&D efforts.
•REGIONAL IMPACTS
Impacts of the new technology will be felt largely in regions where
today's production facilities are located, shown for several industries
in Figure 1 . As can be seen by this figure regions with the heaviest con-
cent rat ion of industrial development, such as the Gulf region and the Great-
Lakes area, would be expected to experience the greatest impact.
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TABLE 5
AREAS FOR RESEARCH AND DEVELOPMENT IN POLLUTION CONTROL
Air
Fine particulate
This would include
participates re:nl
smokes and sublm.'
as Mercury, arseni
Collection or cont
emissions frcn prc
Be ttcr definition c
and biological iry
ing emissions witl
ing more quant it,it
establishing ei.iss
a. Gases such as 5
b. Metallic smoke;
removal technology.
especially thos'e
-ing from metallic
f substances such
_ , zinc , etc.
rol of fugitive
ess equipment
'. the environmental
lets of the f-illow-
respect to obtain-
ive knovledi'.f for
icn regulations.
Ox, >!0x, CO, F, Cl, J.'H.
c. Organic cor.pom ds that have hieh
snog chavactcri ;tics or carcinogenic
aspects
Odor Control
Better definiticn of the envircnrontal
and biolorical irpart of sut>str.r" '.'S which
cannot be rr-p.oved ^y best available teci-.!ir-i
ecor.ociical ly ac!;i cvabl e . This will include
principally, r.elals ."-i-i or^ar.ic coir.pounr.s
that have long biological half-lines or
carcinogenic effects.
Suspended solids removed fro-i treated -
wastcwateis
Color Removal
Renoval of dissolved metals
Improved instrunientation for rapid
monitoring and recovery of waterborne
pollutants
Sol_id Wastes
Demonstration of adequate landfill
disposal techniques
Dcironstrnton of thornal destruction
technologies
Research into the t-ethod;; of ca t evor i ;a--
tioa, i ei'ulat ion an.'. UT\| i i-t iuuio 1 op i c;.
for tout-oiling the disposal of solid
wastes
(1) DenoLos First Level Priority -23-
(2) Denotes Second Level Priority
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TABLE 6A
AIR POLLUTION CONTROL R&D
Research Area
Number of Industries
Represented
Priority Lovcl
• Fine Participate
« Fugitive Emissions
» Quantifying impacts
-S0y, NO , CO, etc.
x x
— Metallic Smokes
— Organic Compounds
o Odor Control
9 Instrumentation
(Rapid Monitoring)
FJ£Sj.
10
6
9
6
5
2
Second
0
5
1
2
1
1
2
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TABLE 6B
WATER POLLUTION CONTROL R&D
Research Area
•» Quantifying Impacts of
Metals/Ortjnnics
e Removal of Suspended
SoSids
— Refractory Orcjantcs
— Coioi
- Dissolved Metals
o instrumentation
(Rapid IVionitOi ing)
Number of Industries
Represented
Priority Level
First
2
2
3
2
Second
4
1
1
4
4
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TABLE_6C
SOLID WASTE R&D
Research Area Number of Industries
Represented
Priority Level
Fijst Sec OIK)
o Landfill Disposal 5 7
e Thermal Destruction 3 3
* Categorization, Rnyula ion,
Legal Methodologies 10 3
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