EPA-600/2 77-023a
January 1977
Environmental Protection Technology Series
INDUSTRIAL PROCESS PROFILES FOR
ENVIRONMENTAL USE: Chapter 1.
Introduction
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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EPA-600/2-77-023a
January 1977
INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE:
CHAPTER 1. INTRODUCTION
by
I. A. Jefcoat and P.W. Spaite (Consultant)
Terry Parsons, Editor
Radian Corporation
P.O. Box 9948
Austin, Texas 78766
Contract No. 68-02-1319, Task 34
ROAPNo. 21AFH-025
Program Element No. 1AB015
EPA Project Officer: I.A. Jefcoat
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
BBS ear ch Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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TABLE OF CONTENTS
INTRODUCTION
USES OF IPPEU
APPROACH TO CATALOG DEVELOPMENT
CATALOG FORMAT
Page
. 1
. 1
. 2
. 5
PRESENT STATUS - FUTURE PROGRAMS , 9
IPPEU NOMENCLATURE 9
Figure
1
LIST OF FIGURES
EXAMPLE SCHEMATIC PROCESS FLOW SHEET. CRUDE SEPARATION
SEGMENT OF THE PETROLEUM REFINING INDUSTRY (Chapter 3).
EXAMPLE PROCESS DESCRIPTION. PROCESS NO. 2, DESALTING
FROM CRUDE SEPARATION SEGMENT OF THE PETROLEUM REFINING
INDUSTRY (Chapter 3) ...
Table
1
2
3
LIST OF TABLES
BASIC RAW MATERIALS FOR U.S. FOSSIL FUEL, METAL, AND
CHEMICAL INDUSTRIES ..
Page
CURRENT STUDIES INCLUDED IN THE INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE 6
PLANNED OR CURRENT INDUSTRY STUDIES FOR FUTURE EFFORTS IN
THE INDUSTRIAL PROCESS PROFILES FOR ENVIRONMENTAL USE... 10
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INTRODUCTION
The catalog of Industrial Process Profiles for Environmental Use (IPPEU)
has been developed as a reference source for information that is useful in
various efforts to determine the environmental impacts of industrial activity
in the U.S. For purposes of organization, the whole of our industrial activi-
ties has been divided into "industries" which have been defined as groups of
companies that are competitively producing similar products from the same types
of raw materials. Generally, industries defined in this way will employ simi-
lar technologies, have common types of environmental impacts, and will be sup-
plying their products for further processing or consumption to the same general
population of customers. Each industry is designated a chapter in the catalog.
Chapters are numbered consecutively and bound individually. In all* twenty-
five chapters are presented in this, the first edition of IPPEU.
USES OF IPPEU
An environmentally oriented central file of industrial process informa-
tion is expected to have many uses. Some of those applications that are
readily identified include:
1. A system of cataloging relevant information which has
been generated by air, water, and solid waste groups
who have been conducting industry studies.
t
2. The formation of an industry-process-pollutant matrix
that highlights those emissions to air, land, and water
that are-most significant and those that are known to
be hazardous.
3. The identification of possible new waste stream problems.
4. Provision of process synopses for quick reference and
bibliography of sources for more complete information.
5. Means for gaining individual industry and process
perspective as well as perspective on industry inter-
relationships.
6. A basic knowledge of the processes that will allow the
full range of environmental control strategies to be
studies and evaluated.
7. Aid in coordinating EPA's research program and efforts
in air, land, and water pollution abatement.
8. Identification of process and waste stream information
that is not known, resulting in the initiation of more
efficient and comprehensive characterization programs.
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9. Establishment of research priorities based on source as-
sessment of the waste streams from readily identifiable
processes.
10. Providing process and waste stream information to help
in designing test programs, source sampling equipment,
and process control equipment.
11. Use by educators as a research reference source and
teaching aid.
12. Use by industrial consultants and designers to broaden
the applicability of their knowledge as well as pinpoint
their areas of expertise.
APPROACH TO CATALOG DEVELOPMENT
Early in the program, consideration was given to use of the Department
of Commerce's Standard Industrial Classification (SIC) Manual as a basis of
defining industries. It was concluded that while some SIC categories seemed
to be appropriate, others were not. It was decided that industries would be
identified through analysis of present commercial and industrial practices.
As a first step, all industrial categories in the SIC were analyzed and the
following six industry categories were identified:
1. Fossil fuel extraction - (e.g., oil and gas, coal),
2. Mineral extraction and chemical processing - (e.g., iron and
steel petroleum refining* industrial organic chemicals),
3. Agricultural and forest products - (e.g., pulp and paper,
grain farming),
4. Compounding and fabrication - (e.g., motor vehicles, machine
tools, paint and varnish),
5. Public service industries - (e.g., utilities, sewage treatment),
and
6. Public service (trade and commerce) - (e.g., gasoline stations,
dry cleaning, auto repair).
In development of the catalog to date, primary attention has been given
to those industries which process primary raw materials such as ores, non-
metallic minerals, coal and oil (category 2 above). The primary raw materials
for industries in category 2 are shown in Table 1. After extraction, most
of the raw materials are used in one of more of the following three ways:
(1) directly and innocuously consumed after a relatively simple pretreatment
(sand and gravel, limestone, etc); (2) used after physical processing to
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Table 1. BASIC RAW MATERIALS FOR U.S. FOSSIL FUEL,
METAL, AND CHEMICAL INDUSTRIES
(APPROXIMATE CONSUMPTION)
Component
Tg/Yr
Oil and Gas
Sand and Gravel
Stone (Limestone)
Coal
Copper, Lead, Zinc Ores
Iron Ores
Lake Brines, Sea Water, Evaporites
Phosphate Rock
Clays
Titanium-Thorium-Zirconium Ore
Molybdenum Ore
Gypsum
Bauxite
Sulfur
Gold and Silver Ores
Uranium - Vanadium Ore
Pumice
Manganese Ore
Feldspathoid Minerals
Bari te
Fluorspar
Nickel Ore
Talc and Soapstone
Chromite
Silicon Ore
Asbestos
Tungsten
Other Minerals (Abrasives, Graphite, Kyonite,
Mica, Peat, Pearlite, Vermiculite)
Other Ores (Antimony, Beryllium Columbium, Tantalum,
Mercury, Rare Earth, Platinum)
1420
834
700
600
396
268
210
116
42
25
20
15
14
8.6
7.8
5.4
3.3
1.9
1.8
1.7
1.7
1.5
1.0
0.9
0.8
0.7
0.7
2.1
1.5
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purify and/or put the material in forms required for further use in industry
(talc for the paint industry, gypsum for plaster of pans, etc.); and (3) feed-
stocks for processes which extract and/or refine metals and chemicals which
are in turn either used as chemical intermediates or supplied for direct
usage as solvents, fuels and other products for direct consumption (e.g.,
petrochemical feedstocks for organic synthesis or crude oil refining to
produce distillate fuel oil). Those industries producing metals and chemicals
and downstream industries which are in the chain leading to consumer products
involve some 12,000 processes which include the industrial activities having
greatest potential for environmental impact; hence, these have been given
first consideration.
Additional subjective bases for selection of industries to be considered
for later issues and for assigning priorities in their evaluation were used.
For the industries involving food and forest product (category 3) only those
whose environmental impacts are considered as bad as or worse than the mineral-
based industries were considered. Several activities classified as compounding
and fabrication (category 4) were considered desirable for study because of
important associated environmental effects. Industries involved with public
service activities (categories 5 and 6) were considered beyond the scope of
the first edition. High priorities were established for industries involving
process materials having published adverse health effects.
After identification of the primary raw materials, the usage of products
and by-products from the industries consuming the primary raw materials was
traced; e.g., the oil and gas production industry supplies feedstocks for the
petroleum refining industry which in turn supplies feedstocks for the basic
petrochemicals industry and the industrial organic chemicals industry (I.O.C.I.)
A significant fraction of the petrochemical industry's output serves as ad-
ditional feedstock to the I.O.C.I. This industry produces some 400 chemicals
which are the building blocks for many industries such as organic dyes and
pigments, pesticides, medicinal chemicals, etc. The complexities of some of
these downstream industries can be illustrated by considering that the organic
dyes and pigments industry converts some 100 raw materials through approxi-
mately 900 intermediate chemicals into more than 2000 color products.
Industries to be considered were defined by assessing the commonality of
raw materials, products, and markets for populations of companies which were
believed to represent a "real world" industry. In some situations this was a
relatively simple task as in the cases of the petroleum refinery industry, the
iron and steel industry, and the primary aluminum industry. For others such
as those involving synthetic organic products the task was more complex. De-
finition of industry boundaries in this situation involved first identifying
companies primarily in the business of producing organic chemicals for further
conversion. The boundaries of the I.O.C.I, were established by starting with
10 basic petrochemical feedstocks and constructing a chemical tree which showed
downstream derivative chemicals. The tree was terminated when the chemical
species under consideration were shown to be predominately feedstocks for one
or more other industries. These other industries involved a significantly
different population of companies which converted the industrial organic
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chemical (i.e., mainly solvents and chemical intermediates) into products for
consumption; e.g., organic dyes and pigments, plastics and resins, and synthetic
fibers. The high level of integration of the larger companies in the I.O.C.I.
with downstream industries made this industry definition task difficult in some
instances, but it is felt that the boundaries as presently established are
sufficiently precise to (1) permit understanding of the realtionship between
products, and (2) identify all processes with significant environmental impact.
The industries described in this effort are shown in Table 2.
CATALOG FORMAT
After identification of an industry the next step was to identify the
environmentally significant processes which make up the industry. This was
accomplished by considering the kinds of equipment and the nature of the input
and output materials for each processing step involved in the conversion of
input raw materials into products. Based on this information a schematic
process flow sheet of the type shown in Figure 1 for the crude separation
segment of the petroleum refining industry was developed. After identifica-
tion of industry boundaries and the population of processes of concern,
process descriptions were developed. Figure 2 illustrates the format for
the process descriptions. The example is process description number 2,
Desalting, from the Crude Separation Segment of the Petroleum Refining
Industry.
The format for each chapter consists of the following elements:
• Industry Description
raw materials
products
companies
environmental impact
bibliography
• Industry Analysis
Segment A
chemical (product) tree
process flowsheets
process descriptions
Segment B, etc.
• Appendices
raw material list
product list
company list
other pertinent data
The industry description discusses the companies, raw materials, products.
and environmental impacts in broad terms. These are typically 10-20 pages in
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Table 2. CURRENT STUDIES INCLUDED IN THE
INDUSTRIAL PROCESS PROFILES FOR
ENVIRONMENTAL USE
Chapter
No. Industry
2 Oil and Gas Production
3 Petroleum Refining
4 Carbon Black
5 Basic Petrochemicals
Industrial Organic Chemicals
7 Organic Dyes and Pigments
8 Pesticides
9 Synthetic Rubber
10 Plastics and Resins
11 Synthetic Fibers
12 Explosives
13 Plasticizers
14 (Reserved for Surfactants)
15 Brine and Evaporite Chemicals
16 Fluorocarbon-Hydrogen Fluoride
17 Gypsum and Wall board
18 Lime
19 Clay
20 Mica
21 Cement
22 Phosphate Rock & Basic Fertilizer Materials
23 Sulfur, Sulfur Oxides & Sulfuric Acid
24 Iron and Steel
25 Primary Aluminum
26 Titanium
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TO SALES
TO SALES AND
REFINERY FUEL
TO SALES
}-
TO LK1HT
HYDROCARBON
PROCESSING
UCCD\
P/
"' ^noiSTILLATt
^_^
H
J>
VACUUM I
DISTILLATION
?l
^ fro MIDDLE AND HEAVY
^[DISTILLATE PROCESSING
OQASEOUS EMISSIONS
A LIQUID EMISSIONS
O SOLID EMISSIONS
TO RESIDUAL
HYDROCARBON
PROCESSING
FIGURE 1. EXAMPLE SCHEMATIC PROCESS FLOW SHEET. CRUDE SEPARATION SEGMENT OF THE
PETROLEUM REFINING INDUSTRY (CHAPTER 3)
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CRUDE SEPARATION PROCESS NO. 2
Desalting
1. Function - The desalting unit is generally the first processing unit in a
crude oil refining scheme. This process is used to'remove salt, water,
and water soluble compounds from the crude, as these compounds can eventually
result in equipment fouling, corrosion, or possible catalyst poisoning in
downstream processing units.
Water 1s added to the incoming raw crude and thoroughly mixed. The wet
crude is then heated to break emulsions and the water and dissolved im-
purities are separated. Separation is accomo1, ished by physical decanting
and electrostatic coalescing. The separated water is collected and sent
to the waste water treating system, and the deslated crude is preheated
and sent to the atmospheric distillation column.
2. Input Materials - The fuel to the desalting unit is crude oil from storage.
3. Operating Parameters -
Temperature: 38-155°C (100-300°F)
Pressure: 2.8+ kg/sq cm (40+ psi)
4. Utilities -
Thermal Energy: 34,800 kcal per m3 of crude charge (22,000 Btu/bbl)
may be obtained by heat exchange with a hot stream
from the distillation column or by process heaters
Electricity: .063 kWh/m3 - used to run pumps and the coalescer
Process Water: 35-60 liters per m3 of crude charged (1.5-2.5.gal/bbl)
5. Waste Streams - Only a liquid effluent is released from this unit. The
effluent rate is about 47 liters per m3 of oil processes. The largest
waste water contaminants are dissolved solids (average concentration
3700 ppm) which are composed largely of chlorides, sulfates, and bi-
carbonates. Oil, phenols, and sulfides are also found, but in lesser
concentrations. Average concentrations for these pollutants are 169,
15, and 4 ppm, respectively.
6. EPA Source Classification - None exists.
7. References
TT)Hack, H., et al., Development of an Approach to Identification of
Emerging Technology and Demonstration Opportunities, EPA 650/2-74-
048, Columbus, Ohio, Battelle-Columbus Labs., 1974.
(2) "Hydrocarbon Processing Refining Processes Handbook". Hydrocarbon
Proc. 53(9), (1974).
(3) Radian Corporation, A Program to Investigate Various Factors in
Refinery Siting. Final Report, Contract No. EQC 319, Austin, Texas,
1974.
FIGURE 2. EXAMPLE PROCESS DESCRIPTION. PROCESS NO. 2.,
DESALTING, FROM CRUDE SEPARATION SEGMENT OF
THE PETROLEUM REFINING INDUSTRY (CHAPTER 3)
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length and are intended to present environmentally oriented overview informa-
tion for middle managers. The industry analysis section presents the process
flowsheet and information on individual processes and their interrelationships.
Process descriptions typically are 1 to 2 pages long. Information on effluent
streams and other environmentally relevant information is presented chiefly
for project managers and others interested in process details. The chemical
(product) tree gives an overview for material flow through the industry. The
appendix presents detailed information on companies, raw materials, products
and environmental impacts. Other pertinent data too lengthy to include with
the process or industry descriptions are also in the appendix.
It is expected that some industry entries will depart from the standard
format. For example, the organic dyes and pigments industry is too complex
to permit development of industrial process descriptions for each of the several
thousand involved. In this situation class descriptions are presented for
the more important color products, and the interrelationships within the
industry segment involving production of intermediates are depicted by a
chemical tree rather than a detailed process flow sheet.
"~-v,
Boilers represent another special situation in that the types of boilers
used will generally be common to many industries. It is anticipated therefore
that a special boiler catalog entry will be developed.
PRESENT STATUS - FUTURE PROGRAMS
This effort contains 24 completed industry catalog entries. An additional
15 will be needed to complete the assessment of those industries based on ex-
tracted minerals (category 2). It is anticipated that the ten most offensive
industries based on food and forest products (category 3) will be considered.
In addition, work will be undertaken to define problems associated with the
compounding and fabrication industries. A listing of planned or current in-
dustry studies is shown in Table 3. Revision to published entr-'es are antici-
pated as the need arises.
Computer storage of the data contained in each chapter is possible. This
will allow the rapid assembly of data based on a particular emission with its
associated processes and industries. The utility of the catalog would be
increased by this ability to rapidly identify the known sources of a particular
emission. The computer program could be flexible enough to allow the retrieval
of data based on a compound, product, process, control device, or industry.
:1f not art-
Suggestions for improving the catalog are welcome. The usefulness of
the catalog to people involved with environmental problems can best be met by
feedback from the users of the IPPEU.
IPPEU NOMENCLATURE
The following nomenclature has evolved based on work done by and for the
EPA Control Systems Laboratory.* These are working definitions in the true
*Now the Industrial Environmental Research Laboratory, Research Triangle Park,
North Carolina.
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Table 3. PLANNED OR CURRENT INDUSTRY STUDIES FOR FUTURE EFFORTS IN THE
INDUSTRIAL PROCESS PROFILES FOR ENVIRONMENTAL USE a
Mineral and Fossil
Fuel Base
Agricultural and
Forest Products
Fabrication
and Compounding
Surfactants
Secondary Non-Ferrous Metals
Industrial Inorganic
Chemicals
Primary Metals
Ferroalloy
Iron Founderies
Antimony
Beryllium
Columbiurn-Tantalum
Copper
Gold
Lead-Zinc
Manganese
Mercury
Molybdenum
Nickel
Platinum Group Metals
Rare-Earth Metals
Silver
Thori urn
Tin
Tungsten
Urani urn
Vandium
Zirconium
Metals Mining
Medicinal Chemicals
Rubber Processing Chemicals
Nuclear Fuels
Barium Chemicals
Coal Mining and Preparation
Glass
Ceramics
Catalysts
Flavor and Perfume
Pulp and Paper
Wood Chemicals
Agricultural Industries
Vegetable Oil
Wet Corn Milling
Seafood Processing
Meat Processing
Rendering
Coffee Roasting1
Enzymes
Paint and Varnish
Soaps and Detergents
Textiles
Printing Inks
Rubber Products
Plastic Products
Printing and Publishing
Adhesives and Sealants
Lubricating Oils and
Greases
10
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Table 3 (Continued). PLANNED OR CURRENT INDUSTRY STUDIES FOR FUTURE EFFORTS
IN THE INDUSTRIAL PROCESS PROFILES FOR ENVIRONMENTAL USE3
Mineral and Fossil Agricultural and Fabrication
Fuel Base9 Forest Products and Compounding
Asbestos
Silicones
Si Icon Metal
Pumice
Talc and Soapstone
Asphalt
Other Minerals
Graphite
Kyanite
Peat
Pearlite
Vermiculite
Activated Carbon
Chealting Agents
Inorganic Color Pigments
Inorganic White Pigments
Radioactive Chemicals
• • • •- — ~ —' - .... I., ... — ...in. - . i i. i ..... ..... I. i i ... — — —
Industrial and Commercial Boilers, Electric Utilities, and Chemical Waste
Processing are also planned studies.
11
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sense, because some were developed during the preparation of chapters in this
first edition. The catalog resulted from the work of many contributors from
different companies,, Some of the chapters in this first edition employ no-
menclature which differs from the definitions listed here = For instance,
the word segment is used for the concept defined here as plant or operation.
While these variations occur in many chapters, nomenclature is generally con-
sistent within each chapter.
1. RAW MATERIALS are feed materials for "processes." They are
of two types: primary raw materials that are used in the
chemical form in which they were taken from the land, water,
or air and secondary raw materials that are produced by other
"industries."
2. INDUSTRIES are made up of groups of "companies" that are
considered competitors in production.of the same products.
Industries have an identifiable population of companies
and have a high degree of commonality with respect to raw
materials consumed, processes employed, products produced,
environmental control problems experienced, pollutants pro-
duced and control equipment used.
3. SEGMENTS are separate groups of companies within an industry.
The companies within a segment form a subset. They may differ
from other companies in the industry in one or more of the
elements in the definition for industries. The companies in a
segment may also employ processes and produce products that
are classified in the industry as a whole or in other indus-
tries.
4. PROCESSES can be considered the basic units that collectively
describe industries. All industries are in practice made up
of sets of processes that have some degree of environmental
impact associated with their operation. Processes are em-
ployed to produce chemical or physical transformation of
input materials into "end products", "intermediate products",
secondary raw materials or waste materials. Input materials
can include primary or secondary raw materials, waste materials,
or intermediate products.
5. PROCESS STEPS are the basic components of a process that utilize
process equipment or materials handling equipment. (Process
equipment includes only those components essential to economic
operation of a process and does not include "control equipment.")
6. SOURCES are process steps from which significant amounts of
emissions to the environment occur.
7. CONTROL EQUIPMENT is equipment whose primary function is to
reduce emissions to the environment. Its presence is not es-
sential to the economic viability of the process.
12
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8- COMPANIES include corporate subdivisions that have a product
slate similar to other companies in an industry.
9. PLANTS OR OPERATIONS are comprised of collections of processes
to produce the products associated with their industry. Indi-
vidual plants within an industry may employ different combina-
tions of processes but all plants will be comprised of some of
the processes that are common to the industry.
10. END PRODUCTS include only those process outputs that are
marketed for use or consumption in the form that they exit
from the process. After use, an end product becomes a
"waste material."
11. INTERMEDIATE PRODUCTS are process output streams that go either
to other processes in the same industry in which they are pro-
duced, or to other industries where they become secondary raw
materials.
12. WASTE MATERIALS are either process outputs that go to a
scavenging industry, or are used end products that are
disposed of or processed to recover reusable constituents.
13. WASTE STREAMS are a non-product discharge to the ambient air,
water, or land from an energy system or industrial process.
13
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TECHNICAL REPORT DATA
(Please read'Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-77-023a
2.
NTIS No. PB 266274/AS
3. RECIPIENT'S ACCESSION-NO.
I. TITLE AND SUBTITLE
Industrial Process Profiles for Environmental Use:
Chapter 1. Introduction
5. REPORT DATE
January 1977
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Terry Parsons, Editor
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
Radian Corporation
P.O. Box 9948
Austin, Texas 78766
1AB015; ROAP 21AFH-025
11. CONTRACT/GRANT NO.
68-02-1319, Task 34
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Initial; 8/75-11/76
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES Authors are I. A. Jefcoat and P.W.Spaite (Consultant). IERL-RTP
project officer Jef coat is no longer with EPA: contact G. Tucker, IERL-RTP, Mail
Drop 63, 919/541-2745;
TR
16. ABSTRACT
The catalog was developed to aid in defining the environmental impacts of U.S. indus-
trial activity.'" Entries for each industry are in consistent format and form separate
chapters of the catalog. Chapter 1 is an introduction to the catalog and identifies a
number of expected uses for the information contained in the various chapters. It
explains the approach to catalog development, as well as the basic catalog format.
It provides examples of typical information to be found in subsequent chapters, along
with definitions for specific catalog nomenclature. It presents plans for future
programs for the assessment of industrial processes and their impact on the environ-
ment.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
COSATI Field/Group
Pollution
Industrial Processes
Chemical Engineering
Process Assessment
Environmental Impact
13B
13H
07A
3. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport}
Unclassified
21. NO. OF PAGES
17
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
14
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