Prepubliaation issue for EPA libraries
and State Solid Waste Management Agencies
ASSESSMENT OF INDUSTRIAL HAZARDOUS WASTE PRACTICES,
RUBBER AND PLASTICS INDUSTRY
Plastic Materials and Synthetics Industry
This report (SW-l63a.2) describes work performed
for the Office of Solid Waste under contract no. 68-01-2194
and is reproduced as received from the contractor.
The findings should be attributed to the contractor
and not to the Office of Solid Waste.
Copies will be available from the
National Technical Information Service
U.S. Department of Commerce
Springfield, Virginia 22161
This report was prepared by Foster D. Snell, Inc., Florham Park,
New Jersey, under Contract No. 69-01-3194.
Publication does not signify that the contents necessarily reflect the
views and policies of the U.S. Environmental Protection Agency, nor
does mention of commercial products constitute endorsement by the L
U.S. Government.
An environmental protection publication (SW-163c.2) in the solid waste
management series.
U.S. ENVIRONMENTAL PROTECTION AGENCY
1978
-------
This report was prepared by Foster D. Snell, Inc., Florham Park,
New Jersey, under Contract No. 69-01-3194.
Publication does not signify that the contents necessarily reflect the
views and policies of the U.S. Environmental Protection Agency, nor
does mention of commercial products constitute endorsement by the
U.S. Government.
An environmental protection publication (SW-163c.2) in the solid waste
management series.
-------
ACKNOWLEDGEMENTS
The preparation of this report was accomplished through
the efforts of the staff of Poster D. Snell, Inc., a subsidiary
of Booz.Allen & Hamilton Inc., Florham Park, New Jersey.
Mr. Matthew A. Straus, Staff Engineer, Hazardous Waste
Management Division, was EPA Project Officer for the study.
His assistance, leadership, careful review and advice made an
invaluable contribution to the preparation of this final
report.
Appreciation is extended to the following trade associations
for assistance and cooperation in this program:
Rubber Manufacturers Association
International Institute of Synthetic
Rubber Producers
Manufacturing Chemists Association
Textile Economics Bureau
Society of the Plastics Industry
Appreciation is also extended to the many rubber products
manufacturers, plastic resin, synthetic rubber and fiber
producing companies, who cannot be mentioned by name due to
reasons of confidentiality, without whose assistance this
report could not have been written.
Acknowledgement is also made of state and Federal agencies
who gave invaluable assistance and cooperation in this program.
-------
TABLE OF CONTENTS
CHAPTER II — PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY — SIC 282
Section Page
1. Introduction And General Description Of The II-2
Plastic Materials And Synthetics Industry
1.1 In 1972, SIC 282 Industries Employed Over 160 II-2
Workers And Produced Approximately $10 Billion
In Shipments
1.2 Many Of The Production Units In This Industry II-4
Are Part Of Large Plant Complexes
1.3 Polymerization And Spinning Are The Two Major II-4
Operations In SIC 282 Used For The Manufacture
Of Their Products
1.4 There Are Eight Major Classes Of Ingredients II-5
Which Are Used In The Manufacture Of Polymers
And Manmade Fibers
1.5 Products Produced By SIC 282 Are Critical In The II-5
U.S. Economy
1.6 Wastes Generated By SIC 282 Establishments Are II-8
Generally Produced Directly As a Result Of The
Unit Operations
1.7 A Significant Portion Of The Wastes Generated 11-10
By SIC 282 May Be Potentially Hazardous
2. Charaterization Of The Plastics Materials .And 11-11
Synthetics Industry
2.1 Structure Of The Plastics Materials And Resins 11-13
Industry, SIC 2821
2.2 Structure Of The Synthetic Rubber (Vulcanized 11-30
Elastomer) Industry, SIC 2822
2.3 Structure Of The Manmade Fiber Industry, SIC 11-49
2823 And 2824
iv
-------
TABLE OF CONTENTS
Section Page
3. Process Descriptions And Waste Stream Identi- 11-66
fication For The Plastics Materials And
Synthetics Industry, SIC 282
3.1 Introduction 11-67
3.2 Detailed Process Descriptions 11-72
4. Waste Characterization For The Plastic 11-125
Materials And Synthetics Industry
4.1 Waste Stream Characterization In Polymerization 11-125
Operations
4.2 Waste Stream Characterization In Spinning 11-135
Operations
4.3 Potentially Hazardous Waste Streams And The 11-137
Criteria For Their Classification
4.4 Waste Quantification For The Years 1974, 1977 11-145
and 1983 (Plastic Materials And Synthetics
Industry)
5. Treatment And Disposal Technology For Poten- 11-165
tially Hazardous Wastes In The Plastic Materials
And Synthetics Industry, Sic 282
5.1 Treatment And Disposal In SIC 282 11-166
5.2 Treatment And Disposal In SIC 282 By Hazardous 11-169
Waste Type
5.3 Treatment And Disposal Technology Levels As 11-174
Applied To Potentially Hazardous Wastes
Produced By The Plastic Materials and Syn-
thetics Industry, SIC 282
6. Cost Analysis For The Treatment And Disposal 11-182
Of Potentially Hazardous Wastes In The Plastic
Materials And Synthetics Industry, SIC 282
6.1 Cost Elements And Treatment Of Costs 11-183
-------
TABLE OF CONTENTS
Section
6.2 Case Study Of Potentially Hazardous Waste
Treatment And Disposal Costs
6.3 Costs Of Disposal Of Potentially Hazardous 11-202
Wastes Affecting The Various Segments Of The
Plastics Materials And Synthetics Industry,
SIC 282
vi
-------
LIST OF TABLES
CHAPTER II — PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY, SIC 282
Table Page
II-l 1972 Structure Of The Plastic Materials II-3
And Synthetics Industry, SIC 282
II-2 Major Classes Of Ingredients Used In The II-6
Manufacture Of Polymers And Manmade Fibers
II-3 Consumption Of Products Produced In II-7
SIC 2821
II-4 Estimated Product Volume Of Principal 11-12
Products Of The Plastic Materials And
Synthetics Industry, SIC 282 (1974)
II-5 Geographic Distribution Of Production 11-15
Units And Capacities In SIC 2821,
Plastics Materials And Resins
II-6 Estimated 1974 Geographic Distribution Of 11-23
Plants And Employment In SIC 2821
II-7 Production Unit Size Distribution By 11-22
Employment SIC 2821 (National Basis)
II-8 Estimated 1974 Geographic Distribution Of 11-25
Total Production Units And Total Production,
SIC 2821
II-9 Geographic Distribution Of Production In 11-26
SIC 2821, Plastic Materials And Resins
11-10 Summary Of Geographic Distribution Of 11-32
Production Units And Estimated 1974
Production, SIC 2822
11-11 Estimated 1974 Geographic Distribution Of 11-33
Synthetic Rubber Production
11-12 Estimated 1974 Geographic Distribution Of 11-39
Employment In SIC 2822
11-13 Production Unit Size Distribution By 11-40
Employment, SIC 2822 (National Basis)
vn
-------
LIST OF TABLES
Page
Estimated Plant Age Distribution Of Styrene- 11-41
Butadiene Synthetic Rubber Production Units
11-15 Estimated Plant Age Distribution Of Poly- 11-42
butadiene Production Units
11-16 Estimated Plant Age Distribution Of 11-43
Acrylonitrile-Butadiene Synthetic Rubber
Production Units
11-17 Estimated Plant Age Distribution of Neoprene 11-44
Production Units
11-18 Estimated Plant Age Distribution Of Butyl 11-45
Rubber Production Units
11-19 Estimated Plant Age Distribution of Ethylene- 11-46
Propylene Elastomer Production Units
11-20 Estimated Plant Age Distribution Of Isoprene 11-47
Elastomer Production Units
*
11-21 Total Estimated Plant Age Distribution Of 11-48
Production Units For Major Synthetic Rubbers,
SIC 2822
11-22 Estimated 1974 Geographic Distribution Of 11-52
Production Units And Employment—SICs 2823
And 2824
11-23 Estimated 1974 Geographic Distribution Of 11-53
Plant Age, Cellulosic Manmade Fibers,
SIC 2823
11-24 Estimated 1974 Geographic Distribution Of Plant 11-55
Age Of Non-Cellulosic Synthetic Fibers, SIC 2824
11-25 Summary Of Ages Of Production Units, SIC 2824 11-54
11-26 Estimated 1974 Geographic Distribution Of Plant 11-56
Age, Synthetic Fibers—SIC 2824, Nylon And
Aramid
viii
-------
LIST OF TABLES
Table Page
11-27 Estimated 1974 Geographic Distribution Of Plant 11-57
Age, Synthetic Fibers—SIC 2824, Other Non-
Cellulosic
11-28 Estimated 1974 Geographic Distribution Of Plant 11-58
Age, Synthetic Fibers—SIC 2824, Polyester
11-29 Estimated 1974 Geographic Distribution Of Plant 11-59
Age, Synthetic Fibers—SIC 2824, Polyolefins
And Vinyon
11-30 Estimated 1974 Geographic Distribution Of Plant 11-60
Age, Synthetic Fibers—SIC 2824, Acrylic and
Modacrylic
11-31 Estimated 1974 Geographic Distribution Of 11-62
Cellulosic Fiber Production—SIC 2823 (KKKg/yr.)
11-32 Estimated 1974 Geographic Distribution Of 11-63
Non-Celluosic Fiber Capacities—SIC 2824
(KKKg/yr.)
11-33 Estimated 1974 Geographic Distribution Of Non- 11-64
Cellulosic Fiber Capacities—SIC 2824 (KKKg/yr.)
11-34 Estimated 1974 Geographic Distribution of Non- 11-65
Cellulosic Fiber Production—SIC 2824 (KKKg/yr.)
11-35 Summary Of Production Elements In The Plastics 11-69
Resins Industry—SIC 2821
11-36 Summary Of Production Elements In The Synthetic 11-70
Rubber Industry—SIC 2822
11-37 Estimated Waste Factors Associated With The 11-74
Production of Olefinic Polymers As A Result
Of Total Production—SIC 2822
11-38 Synoptic Description of Spinning Process 11-119
ix
-------
LIST OF TABLES
Table Page
11-39 Summary of Waste Factors In the Spinning 11-124
Operations As A Percent Of Total Production—
SIC 2823 And 2824
11-40 Estimated 1974 Geographic Distribution Of 11-146
Wastes For The Major Polymerization Operations
Of The Plastic Materials And Synthetics
Industry—SIC 282 (Wet Basis) (KKg/yr.)
11-41 Estimated 1974 Geographic Distribution Of 11-155
Wastes For The Spinning Operations Of The
Plastic Materials And Synthetics Industry—
SIC 282 (Wet Basis) (KKg/yr.)
11-42 Total Estimated Wastes For The Plastic Materials 11-157
And Synthetics Industry—SIC 282 (Wet Basis)
(KKg/yr.)
11-43 Product Shipments In Producer Prices For The 11-159
Plastic Materials And Synthetics Industry—
SIC 282
11-44 Projected Average Growth Rate Over 1974 11-160
11-45 Estimated Total Wastes For 1974, 1977 And 11-160
1983 (KKg/yr.)
11-46 Compilation Of The Reported Waste Factors In 11-162
The Polymerization Operations In The Manufac-
ture Of Plastics And Manmade Fiber — SIC 282
11-47 Compilation Of The Reported Waste Factors In 11-164
The Spinning Operations In The Manufacture Of
Manmade Fibers — SICs 2823 And 2824
11-48 Estimated Total Potentially Hazardous Wastes 11-161
For 1974, 1977 and 1983 (KKg/yr.)
11-49 Treatment And Disposal Technologies For Liquid 11-176
Phenolic Wastes—SIC 2821
11-50 Treatment And Disposal Technologies For Solid/ 11-177
Semi-solid Phenolic Waste
11-51 Treatment And Disposal Technologies For Still 11-^178
Bottoms (Aromatics, Aliphatics, Chlorinated,
Etc.) In All SIC 282 Producing Such Waste
Streams
-------
LIST OF TABLES
Table Page
11-52 Treatment And Disposal Technologies For 11-179
Off-Grade Product In Amino Resin Production—
SIC 2821
11-53 Treatment And Disposal Technologies For Waste 11-180
Catalyst Stream In Polyester Production—SIC
2821
11-54 Treatment And Disposal Technologies For Zinc 11-181
Oxide Sludges From Wastewater Treatment In
Cellulosic And Acrylic Fiber Production—SIC
282
11-55 Phenolics Production: Typical Plant Disposal 11-187
Costs For Potentially Hazardous Liquid Wastes—
SIC 2821
11-56 Incineration Costs In Phenolics Production 11-188
11-57 Phenolics Production: Typical Plant Disposal 11-189
Costs For Potentially Hazardous Solid And
Semi-solid Wastes—SIC 2821
11-58 Styrene Butadiene Rubber: Typical Plant Disposal 11-191
Costs For Potentially Hazardous Still Bottoms—
SIC 2821
11-59 Polystyrene: Typical Plant Disposal Costs For 11-192
Potentially Hazardous Still Bottoms—SIC 2821
11-60 ABS-SAN Resins: Typical Plant Disposal Costs 11-193
For Potentially Hazardous Still Bottoms—
SIC 2821
11-61 Polypropylene: Typical Plant Disposal Costs For 11-195
Potentially Hazardous Still Bottoms—SICs 2821
And 2824
11-62 Polybutadiene: Typical Plant Disposal Costs For 11-196
Potentially Hazardous Still Bottoms—SIC 2823
XI
-------
LIST OF TABLES
Page
Level I Disposal Costs In Rayon Production 11-197
Level II Operating Costs For Zinc Recovery 11-198
Unit In Rayon Production
11-65 Level II Disposal Costs In Rayon Production 11-199
11-66 Rayon: Typical Plant Disposal Costs For Zinc 11-200
Contaminated Sludge—SIC 2823
11-67 Level I Disposal Costs In Acrylic And Modacrylic 11-201
Production
11-68 Level II Total Zinc Recovery Costs In Acrylic 11-202
And Modacrylic Production
11-69 Acrylic And Modacrylic: Typical Plant Disposal 11-203
Costs For Zinc Contaminated Sludge—SIC 2824
11-70 Yearly Expenditures For Potentially Hazardous 11-204
Waste Disposal In the Major Segments Of The
Plastic Materials And Synthetics Industry By
T/D Level—SIC 282
11-71 Percent Of Production Value Allocated To Treat.- 11-205
ment And Disposal Of Potentially Hazardous
Waste In the Plastic Materials And Synthetics
Industry—SIC 282
11-72 Synopsis Of The Findings On Treatment/Disposal 11-206
Methods And Costs For The Plastic Materials And
Synthetics Industry—SIC 282
xii
-------
LIST OF FLOW DIAGRAMS
Figure Page
II-l Generalized Processing II-9
II-2 Emulsion/Suspension Polymerization 11-77
II-3 Bulk Or Mass Polymerization 11-79
II-4 Solution Polymerization, Phillips Process 11-82
II-5 Solution Polymerization, Ziegler Process 11-85
II-6 Particle Form Polymerization 11-87
II-7 Acrylic And Modacrylic 11-90
II-8 Nylon 6 (Polyamide) 11-92
II-9 Nylon 6, 6 (Polyamide) 11-93
11-10 Polyester Resin 11-95
11-11 Phenolic Resin 11-98
11-12 Amino Formaldehyde - 11-99
11-13 Coumarone-Indene (Thermal And Solvent Process) 11-102
11-14 Epoxy Resin (Continuous Process) 11-104
11-15 Alkyd Resin (Solvent And Dry Processes) 11-107
11-16 Polyurethane 11-108
11-17 Silicone Products 11-111
11-18 Viscose Rayon 11-114
11-19 Cellulose Acetate Resin 11-116
11-20 Spinning Process 11-118
xl ii
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II. PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY — SIC 282
This chapter characterizes and discusses the industry
structure, the manufacturing processes, the total wastes
generated and their treatment and disposal technologies and
the associated costs for the potentially hazardous wastes
identified for the Plastic Materials and Synthetics Industry,
SIC 282.
The chapter's contents are presented as follows:
SECTION 1 — INTRODUCTION AND GENERAL
DESCRIPTION OF THE PLASTIC MATERIALS
AND SYNTHETICS INDUSTRY
SECTION 2 — CHARACTERIZATION OF THE
PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY, SIC 282
SECTION 3 — PROCESS DESCRIPTIONS, WASTE
STREAM IDENTIFICATION AND WASTE CHAR-
ACTERIZATION AND QUANTIFICATION, SIC 282
SECTION 4 — TREATMENT AND DISPOSAL
TECHNOLOGY FOR POTENTIALLY HAZARDOUS
WASTES GENERATED BY THE PLASTIC
MATERIALS AND SYNTHETICS INDUSTRY,
SIC 282
SECTION 5 — COST ANALYSIS FOR THE TREAT-
MENT AND DISPOSAL OF POTENTIALLY
HAZARDOUS WASTES, SIC 282.
All tables and figures follow the text immediately after
they are discussed.
II-l
-------
1. INTRODUCTION AND GENERAL DESCRIPTION OF THE PLASTIC
MATERIALS AND SYNTHETICS INDUSTRY
The following industry segments are included within
SIC 282:
Plastic Materials and Resins SIC 2821
Synthetic Rubber SIC 2822
Cellulosic Man-Made Fibers SIC 2823
Organic Fibers, Non-Cellulosic SIC 2824.
Tables and figures discussed, follow in the section's
text.
1.1 In 1972, SIC 282 Industries Employed Over 160
Workers And Produced Approximately $10 Billion
In Shipments
Table II-l shows the number of employees, value
added, value of shipments, and approximate number of
establishments and companies for the plastic materials
and synthetics industry in 1972. It also presents the
relative importance of each of the SIC 282 segments in
terms of employment and value added. The table is based
on the 1972 Census of Manufacturers and indicates:
These industries have approximately 462 estab-
lishments with 70% within SIC 2821. Similarly,
of the 289 companies reporting in SIC 282,
66% are classified in SIC 2821.
In terms of value added by manufacturers and
value of industry shipments, SIC 2821 is also
most important.
Only in terms of all employees is SIC 2824
the largest.
II-2
-------
282
H
I
CO
TABLE II-l
1972 STRUCTURE OF THE PLASTIC
MATERIALS AWO S'/NTIItTICS INDUSTRY,
SIC 282
SIC
Co,i,!1)
2821
2822
2823
2824
All 1
(thousand)
54.8
11.8
19.0
76.3
;m[' loyt-*'?
Value Added Hy
Manuf act urf
(i of SIC J82)
(33
(7
(11
(47
.8)
.3)
.7)
.1)
($ tui 1 lion)
2,160.5
491.7
252.7
2,031.1
('(. of SIC .'82)
(43
(10
('->
(41
.8)
.0)
.1)
.11
Valui- Of Intiu.stry
Shipments
($. mi 1 1 ion)
4,478.2
1 ,089.4
627.9
3,601.4
(I of SIC 282)
(45.7)
(11.1)
(0.4)
(3f,.8)
Approximate Number
of Establishments
(number)
323
5y
20
60
(% of SIC 282)
(70.0)
(13.0)
(4.0)
(12.0)
Companies
(number)
191
50
13
35
(% of SIC 282)
(66.0)
(17.3)
(4.5)
(12.2)
161.9
4,936.0
9,746.9
462
289
Note:
(1)
(2)
SIC Codes by industry group and industry are:
2821 Plastic Materials and Resins
2822 Synthetic Rubber
2821 Celluloiic Man-Made Fibers
2824 Oryanic Fibers, Non-Cullulosic
262 Plastic Materials and Synthetics
A company, as the term is used in the Census of Manufacturers, is a business oryanization
consisting of one establishment or more under common ownership or control.
Source: U.S. Bureau of Census, Census of Manufacturers, 1972 Industry Series: Plastic
Materials, Synthetic Rubber and Man-Made Fibers, MCT2(2)-2flJ(, U..S. Government
Printing Office, Washington, D.C., 1974.
-------
1.2 Many Of The Production Units In This Industry Are
Part Of Large Plant Complexes?
The Census Bureau classifies or segments industries
in terms of establishments. This technique does not in
many instances represent the proper method for reporting
for the purposes of this study. This is due to the fact
that establishments as reported in the Census may be
manufacturing several classes of products both within
and outside the scope of this study. This situation is
the rule rather than the exception for the major plastic
materials, synthetic rubbers and spinning establishments
classified within SIC 282.
Poster D. Snell, Inc., therefore, identified the
the number of production units within the establishments
or plant complexes producing materials classified in
each of the four industry segments of SIC 282. For the
purposes of the study industry structure and waste
quantification are reported in terms of production units
so that a more realistic picture of SIC 282 could be
provided.
A consequence of this approach is that a greater
number of production units are reported in each four
digit SIC by Snell than establishments as reported by
the Census.
1.3 Polymerization And Spinning Are The Two Major
Operations In SIC 282 Used For The Manufacture Of
Their Products
Polymerization is the chemical reaction whereby
repeating units of one or more molecular species are
combined to form a large molecule. While this process
can take several forms, e.g., solution, suspension,
emulsion, etc., it is basic to the manufacture of all
products in this industry.
Spinning operations are significantly different
from the polymerization process in terms of equipment
and type of physico-chemical changes occurring in the
product formation. Fundamentally, this process is the
extrusion of a polymer through a spinneret either in
solution or as a melt to form a fiber.
II-4
-------
1.4 There Are Eight Major Classes Of Ingredients Which
Are Used In The Manufacture Of Polymers And
Man-Made Fibers
The eight major classes of ingredients are presented
in Table 11-2 along with a discussion of their purpose
in the manufacture of products in this industry.
These classes may be divided into two functional
groups:
The first group includes the monomers, cata-
lysts or initiators and carrier fluids which
are the basic feed requirements (raw materials)
for polymer production.
Modifiers, plasticizers, chemical additives,
dyes and pigments and processing chemicals
constitute the second group. These substances
are used to alter the physico-chemical proper-
ties of the product so that they may be further
processed.
The fact that there are two general groups of
ingredients should not be construed as implying a two
step operation in most cases. For instance, in SIC 2822
carbon black and plasticizers are added to the reaction
mixture at the polymerization step, thus producing a
"master batched rubber".
1.5 Products Produced By SIC 282 Are Critical In The
U.S. Economy
This industry produces materials which are broadly
dispersed throughout the U.S. economy and are used in
the subsequent production of a variety of items.
II-5
-------
TABLE U-2
MAJOR CLASSES OF INGREDIENTS
USED IN THE MANUFACTURE OF
POLYMERS AND MAN-MADE FIBERS
SIC 282
I. Monomers
II. Catalysts and
Initiators
III. Carrier Fluids
IV. Modifiers
V. Plasticizers
VI. Chemical Additives
vn. Dyes and Pigments
vni. Processing Chemicals
The building blocks of the resins or
elastomers. Some monomers are
treated by addition of small amounts
of inhibitors to prevent autopolymer-
ization in storage.
These chemicals are introduced to
start the polymerization process and
to accelerate the reaction.
These fluids may be water or organic
solvents added to reduce the viscos-
ity during polymerization and to
improve the heat transfer.
Chemicals which are incorporated in
the basic polymer chains so as to mod-
ify the physical properties (e.g..
rigidity or tenacity) of the product.
Chemicals which are mixed with the
polymers, but are not chemically
incorporated . Their purpose is to
make the polymer more pliable.
These are materials which are added
to the polymer to modify the chem-
ical properties of the product. For
example, this may include antioxi-
dants and photodesensitizers.
These may include organic as well
as inorganic compounds. The dye«
are dissolved in the polymer while
the pigments are physically dis-
persed in the mass. Their purpose
is to mask or impart color to the
polymer.
These chemicals are used to control
pH conditions or other physico-
chemical parameters of the aqueous
streams used in both the polymeriza-
tion and spinning processes.
Source: Foster D . Snell, Inc.
II-6
-------
For example, the following table demonstrates the
pattern of consumption of one of the industry segments—
Plastics and Resins (SIC 2821) for 1970. (Source:
Modern Plastics, July 1973, and Foster D. Snell, Inc.
estimates).
Table II-3 — Consumption Of Products
Produced In SIC 2"82T
Present Consumption of
Market Plastics in 1970
Building and construction 24%
Packaging 27
Transportation 10
Electric/electronics 9
Furniture 4
Housewares 5
Appliances 3
Other 18
Total: 100%
In fact, the "other" category demonstrates the
wide distribution. This category includes toys, textile
and paper treating, agriculture, marine craft, signs,
shoes and phonograph records.
Other SIC 282 products are similarly widely
dispersed. Indeed the products of SIC 2824 constitute
over 90% of all apparel worn in this country.
II-7
-------
1.6 Wastes Generated By SIC 282 Establishments Are
Generally Produced Directly As A Result Of The
Unit Operations
Figure II-l, presents a generalized processing
flow diagram. The following steps or unit operations
are common to many processes within the industry:
Monomer(s) storage
Monomer preparation
Monomer(s) feeding to the reactor
Carrier feeding to the reactor(2)
Catalyst feeding to the reactor
Reaction
Monomer(s) recovery
Carrier recovery(1)
Catalyst removal or recovery(D
Polymer processing.
Waste streams generated by these unit operations
include:
Inhibitor removal from monomer preparation
Still bottoms from monomer and carrier
recovery
Catalyst wastes from catalyst removal or
recovery
Off grade polymer or fiber product from
production upsets which may occur at the
reaction or polymer steps
Sludges from on-site wastewater treatment
facilities.
In addition to these waste streams, others are
generated by spillage in warehousing or storage areas,
the action of particulate emission control equipment,
lubricating oil changes and the discarding of defective
packaging materials.
Notes: (1) Where required.
(2) Except for bulk processes,
II-8
-------
MONOMER 1
STORAGE
MONOMER 2
STORAGE
r— . • — — 1
MONOMER 1 1
|_ PREPARATION J
1 CATALYST
STORAGE
^
r
1 CATALYST
FEED
1
MONOMER 1
FEED
»
1
- — 1
WASTE
INHIBITOR
1;
REACTION
i
1
1
r "" MONOMER^"™ ""
[ FEED _j
CARRIER 1
STORAGE 1
1
1
1
r
CARRIER
FEED
MONOMER
RECOVERY
GRADE PRODUCT
MONOMER STORAGE
STILL BOTTOMS
CARRIER
RECOVERED
CATALYST
I RECOVERY I
I ---- . _ r .1
I fc- - -
'CATALYST REMOVAL |
0 RECOVERY
-. STILL BOTTOMS
PARTICULATE
A
EMISSION CONTROL
EQUIPMENT
POLYMER
PROCESSING
1
k
OFF GRADE PRODUCT
FIGURE II-l. GENERALIZED PROCESSING FLOW DIAGRAM
Note; Unit operations represented by dotted lines do not appear in all of the processes.
Differences between process types are discussed in the text.
Source; Fostert D. Snell, Inc.
-------
1.7
A Significant Portion Of The Wastes Generated By
SIC 282 May Be Potentially Hazardous
Inhibitor wastes generated by monomer preparation,
still bottoms from monomer and carrier recovery and off
grade polymer may in certain cases contain organic
materials which may be toxic or highly flammable.
Catalyst wastes from catalyst removal or recovery
and sludges from on-site wastewater treatment facilities
may contain metal ions such as tin, zinc, cadmium and
nickel. These metals are considered to be toxic.
The potentially hazardous nature of these wastes
varies with the product. Individual waste streams
generated by the processes studied are characterized,
on a case by case basis, in terms of their potential
hazard in Section 4 of this chapter.
11-10
-------
2. CHARACTERIZATION OF THE PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY
Tables D-l through D-4 in Appendix D present a detailed
definition of each of the four industry segments of SIC 282.
Table II-4 lists the principal products of SIC 282 in
the order of decreasing importance in terms of estimated 1974
production volumes. The following conclusions may be drawn
from the table:
The total 1974 estimate of production
volumes for SIC 282 was on the order
of 30,000 KKKg.
The greatest production in terms of
weight was in SIC 2821 and 2824 with
these industries accounting for
approximately 85% of all production
in SIC 282.
SICs 2822 and 2823 only accounted for
approximately 15% of the production
in the plastic materials and synthetics
industry.
There are twenty-one important polymer
types or classes produced by SIC 282
establishments. The first eight,
polyesters, polyamides, polyethylene,
vinyl resins, styrenes, polypropylene,
acrylics and SBR account for over 85%
of the total production by weight in
SIC 282. In fact the first three
account for over 50% of the production.
The remainder of this section details the industry
structure by four digit SIC for each of the segments of the
plastic materials and synthetics industry as follows:
Sub-Section 2.1 — SIC 2821, Plastics
Materials and Resins.
Sub-Section 2.2 — SIC 2822, Synthetic
Rubber.
Sub-Section 2.3 — SIC 2823, Cellulosic
Man-Made Fibers.
Sub-Section 2.4 — SIC 2824, Organic
Fibers, Non-Cellulosic.
11-11
-------
TABLE II-4
ESTIMATED PRODUCT VOLUME OF
PRINCIPAL PRODUCTS OF THE
PLASTIC MATERIALS AND SYNTHETICS INDUSTRY
SIC 282 (1974)
Product
Polyesters
Polyamides
Polyethylene
Vinyl Resins
Styrene Resins
Polypropylene
SBR
SBR
Cellulosics
Phenolics
Polyurethanes
Polybutadiene
Amino Resins
Alkyds
Neoprene
Butyl Rubber
EPM-EPDM
Coumarone-Indene
Isoprene
Epoxy
Silicone
Total Production
6.855(1)
4,727
4,018
2.277
2,284
2,196(1>
2,117
2,116
626
610
538
477
377
317
177
166
166
148
142
113
27
30,474
1
2821
451
52
4,018
2,277
2,284
1,026
301
87
610
53
377
317
148
113
12.078
-IUUUUUUH uy
2822
426
2,116
485
477
177
166
166
142
27^
4,182
oic. rvixivg/yi .
2823 2824
6,440
4.675
1,170
1,390
539
539_ 13.675
SBR = Styrene-Butadiene Rubber.
EPM-EPDM = Ethylene-Propylene Rubbers. EPM are copolymer and EPDM are terpolymers.
Note: (1) The quantity of production listed under SIC 2821 and SIC 2824 may not be additive due to
possible transfers from 2821 to 2824.
Source: Foster D. Snell, Inc.
-------
2.1 Structure Of The Plastics Materials And Resins
Industry, SIC 2821
For this industry in 1972, value added by manufac-
turer was $2,160.5 million according to the 1973 Census
of Manufacturers, while value of shipments was $4,478.2
million. There were over 54,000 employees working in
SIC 2821 in 1972.
The products of this industry (i.e., polyethylene,
polyvinyl chloride, etc.) are used throughout the U.S.
economy with over 50% of production going into building
and construction and packaging materials.
There are literally thousands of resin types
produced by this industry. For the purposes of this
study, the report focuses on those resins which are
responsible for over 95% of the industrial production.
These resins are:
High and low density polyethylene
Polyvinyl chloride
Polyvinyl acetate
ABS-SAN
Polystyrene
Polypropylene
Phenolics and other tar acid resins
Polyesters
Amino resins
Alkyds
Acrylics
Coumarone-Indene and petroleum resins
Polyurethanes
Cellulosic
Epoxy
Polyamides.
Appendix A presents the detailed methodology used
in developing the data presented in the tables for this
industry.
11-13
-------
2.1.1 Geographic Distribution Of Plants And
Their Capacities In SIC 2821
Table II-5 presents the geographic distri-
bution of production units and their capacities for
this industry segment.
Our survey has found that there are
approximately 816 production units
within SIC 2821. This value differs
from the value of 323 establishments
given in the 1972 Census of Manufacturers.
It is felt that this discrepancy is due
to the fact that while the study team
is counting the number of sites where
a particular resin is manufactured, the
Census is, in reality, counting the
number of plant complexes where several
resins may be produced. For the purposes
of the report, the study team's method
of counting is more applicable because
it provides a more realistic overview
of the geographic distribution.
The highest concentration of production
units and capacity is in the Atlantic
states including New Jersey, New York
and Pennsylvania, the Gulf Coast states
such as Louisianna and Texas plus the
states of Ohio, Michigan, Kentucky and
California. In general, these are the
locations of production sites for
petroleum based chemicals required by
the industry for its production processes.
Of the resins produced in SIC 2821, the greatest
capacity exists for polyethylene manufacture with a
total of 4,305 KKKg/yr., followed by polyvinyl
chloride at 2,982 KKKg/yr. and polystyrene with a
capacity for 1,935 KKKg/yr. Lower capacity exists
for such products as epoxy resins at 136 KKKg/yr.
and for polyamides at about 52 KKKg/yr.
11-14
-------
IV
IX
VI
K
I
ni
IV
IX
High Density
Polyethylene
TABLE II-5 (1)
GEOGRAPHIC DISTRIBUTION OF
PRODUCTION UNITS AND CAPACITIES
IN SIC 2821. PLASTICS MATERIALS
AND RESINS
Low Density
Polyethylene
Alabama
Alaska
Arizona
Arkansas
California
VIII Colorado
Connecticut
Delaware
Florida
IV Georgia
Hawaii
Idaho
Number Number
Production Capacity Production Capacity
Units KKKg/yr Units KKKg/yr
55
Illinois
339
VII
IV
VI
Indiana
VII Iowa
Kansas
Kentucky
Louisiana
110
77
145
260
537
I
Maine
HI Maryland
I
Massachusetts
Michigan
Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX
Nevada
VI
New Hampshire
New Jersey
New Mexico
IV
New York
North Carolina
VIH North Dakota
V
Ohio
VI Oklahoma
Oregon
III
Pennsylvania
Rhode Island
IV
South Carolina
Vin South Dakota
IV
VI
Tennessee
Texas
10
990
12
1792
VHI Utah
I
Vermont
III
Virginia
Washington
111 West Virginia
V
Wisconsin
Vin Wyoming
TOTAL
13
1327
20
2978
Region
III
IV
449
VI
12
1250
-IS.
.3329.
vn
77
145
vni
55
Snell, Inc. analytic of data fro*:
Air Pollutant E»i»»ion» trim
U.S. Environmental Protection fcfency.
Protection Technology Ceriec (M fi50/2-74-lM,
October, 1974.
(b) "Supply Statue", Modern Pl««tic«. Vol. 52, Ho. 1, January, 1975
(c) 1974 Final Monthly Statistical Report Plastic t Resin Materials.
SPI etc., SPI Comittee on Resin Statistics aa compiled by
JSrnst & Ernst.
(d) *«la»tic» i Reiins", Chemical Econamic Han4book. Itanford
Reeoareh Inatitut*
11-15
-------
PVC
PVAC
TABLE n-5 <2)
PVA
Number Number Number
Production Capacity Production Capacity Production Capacity
Units KKKB/vr Units KKKa/vr Units KKKn/vr
IV
X
IX
IX
iiu
III
IV
L\
•L:
V
Alaska
Arizona
Arkansas
^Colorado
Connecticut
Delaware 2
Georgia
Idaho
Illinois 2
Indiana
1
US 5
ISO
SS 1
140 3
4
13
2
18
MI Iowa
Vll
IV
VI
i
ni
i
V
V
IV
VII
Kansas
Kentucky 2
Louisiana 4
Maryland 1
Michigan
Minnesota
Mississiopi
Missouri
1
12S 3
357
91 1
242 4
2
16 1 14
1
29 2 68
V m Montana
VII
IX
1
11
'.'I
it
ft
V
VI
\
iii_
1
IV
v in
VI
V'lll
i
in
X
III
V
Nebraska
Nevada
New Hampshire
New Jersey 4
New Mexico
.\*-A *>3rk 2
North Carolina
OJ-.io 4
Oklahoma 1
Oreson
Pernsvivania 1
Rhode Island 1
Soiuh Carolina
South Dakota
Tennessee
Texas 3
Utah
Vermont
Virginia
Washington
West Virginia 3
'Aisconsin
300 s
135 1
1
353 2
100
91
50
425
1
145 2
•u
4
2
12
1 46
i
8
TOTAL 37
Region I 5
II ft
01 7
IV 3
V 6
vn
2982 31
292 4
43S «
577 3
180 6
493 5
1
149 4 128
29 2 68
38
9
26 1 14
30
1 4S
2
vm
PVC
DC 2
X
123 5
1
13
2
- Polyvinyl Chloride PVAC - Polyvinyl Acetate PVA - Polyvinyl Alcohol
r-e: Foster D. Snell, Inc. analysis of data from:
(a) Systems Analysis of Air Pollutant Emissions from the Chemical/
Plastics Industry,
U.S. Environmental Protection Agency,
Environmental Protection Technology Series
October, 1974.
(b) "SupDlv Status", Modern Plastics, Vol. 52.
(c) 1974 Final Monthly
Statistical Report Plast
EPA 650/2-74-106,
No. 1, January, 1975
ic t Resin Materials,
SPI etc., SPI Committee on Resin Statistics as compiled by
Ernst t Ernst.
(d) "Plastics t Resins", Chemical Economic Handbook, Stanford Research
11-16
-------
TABLE II-:
ABS-SAN
Polystyrene
rv
X
IX
VI
IX
vin
i
ni
IV
IV
Number
Production
Units
Alabama
Alaska
Arizona
Arkansas
California 1
Colorado
Connecticut 1
Delaware
Florida
Georgia
Number
Capacity Production Capacity
KKKg/yr Units KKKg.'yr
9 6 315
30 2 125
IX Hawaii
X
V
V
VII
VII
IV
VI
1
ni
i
V
V
IV
vn
VIII
VII
IX
I
II
VI
n
rv
vin
V
VI
X
in
Idaho
Illinois 2
Indiana
Iowa
Kansas
Kentucky 1
Louisiana 2
Maine
Maryland
Massachusetts
Michigan 1
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey 1
New Mexico
New York
North Carolina
North Dakota
Ohio 1
Oklahoma
Oregon
Pennsylvania
114 - 5 360
14
SI
B 395
48 1 BO
1 80
16
1 1:
123 6 475
I" Rhode Island
IV
VID
IV
VI
VIII
I
III
X
111
V
vin
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia 1
Wisconsin
Wyoming
TOTAL 11
Region 1 1
n i
III 1
IV 1
V 4
VI 2
vn
1 90
119
564 33 1935
30 10 s:o
16
119
14 1 15
285 12 915
91 1 SO
1 BO
vni
K 1
9 6 315
X
ABS-SAN • Acrylonitrile-Butadiene-Styrene Resins and Styrene-Acrylonitrile
Source: Foster D. Snell, Inc. analysis of data iron:
(a) Systems Analysis of Air Pollutant Emissions licar, the Cher.ical
Plastics Industry, U.S. Environmental Protection Agency,
Environmental Protection Technology Series EPA 650/2-74-lob,
October, 1974.
(b) "Supply Status", Modern Plastics, Vol. 52, No. 1, January, 1975
(c) 1974 Final Monthly Statistical Report Plastic t «c»in Materials.
SPI etc., SPI Corodttee on Resin Statiiticc a« compiled by
Ernst £ Ernst.
(d) "Plastics t Resin*", Chemical Economic Handbook, Stanford
Research Institute
11-17
-------
TABLE H-5 <«>
Polypropylene
Phenollct and Other
Tar Acid Resins
rv
X
IX
VI
IX
VIIJ
I
III
IV
iv
IX
X
V
V
VII
VII
rv
VI
1
lit
i
V
V
rv
v;i
v:n
VII
IX
i
n
VI
tj
IV
VIII
X
VI
X
in
!
IV
vn
iv
VI
VIII
r
in
X
II!
V
vin
Production
Units
Aiaban-.a
Alaska
.Arizona
Arkansas
California
Colorado
Connecticut
Deiaware 1
Florida
Georgia
Hawaii
Idaho
Ilhnois
Indiana
Iowa
Kansas
Kent-wciv
Lou:r.ir,a 1
Maine
Marvland
Massachusetts
Michigan
Minnesota
Mississippi
MiSiour:
Montana
Nebraska
Nevada
\ew Hsirpshire
S'ew Jersev 1
\'ew Vexira
\-?w York
N: .-•..- Jarc.ir.a
\"cr;- 2ikc:a
Ohio
Ok..-hcna
0---:r.
I" ••" "" » V . Vafl - i
ar. celt .'s.ar.ci
S^u'1- C-.rtiir.a
5. _:.- [Mkrta
T^r.r=55ee
Texa=
L':=h
V-r-on;
Virginia
'.VashinRtor.
l'.'»s: Virginia 1
Wisconsin
Kyoirina
TOTAL 11
Region I
II 1
III 2
IV
V
V! 8
VII
VIII
LX
X
rre: Tostsr D. Sr.ell, Inc. ar.al
fa; 3vst-ir5 Anal\-sis cf A
"liscics Trjuslrv, L'.
Er.viror-^er.tai ?rcic-r:
Dctobv", 1974.
Tc; "S-?cly Status", :•'.::
(c) i:<~-i Fir.i! ••:o-.:r.ly Jt
5?I *tc.r s?l 7onr,itt
Irr.st & Err.st.
(d) "Plastics & Resins",
Research Institute
Capacity Production Capacity
KKKK'vr Units KKKg/yr
1 12
8 55
1 4
US
1 4
1 4
1 12
315
2 32
1 _ 12
1 2
125 5 sn
4 102
4 29
3 117
5 38
585 4 49
2 18
'5
2 36
1215 46 576
3 38
125 9 152
190
6 45
7 169
900 4 49
1 12
1 2
8 55
7 56
ysis of data fron:
ir Poiijtant Enssions from the Chemical''
S. Erwirsnr'er.tal Protection Agency,
-rn Terhnology 3enes EPA 650/2-TJ-106,
r-: ?Usti73, V3l. 52. No. 1, Jar.-ary, 1975
atisticil ?.ocort Flistic & Resin Matsrials,
ae 3* Kesir. ;tjtistics »s conpiled by
Chemical Economic Handbook, Stanford
11-18
-------
TABLE 11-5 (5)
IV
X
DC
V!
DC
vin
i
m
IV
IV
DC
X
V
V
vn
vn
IV
VI
i
in
i
V
V
rv
vn
vm
VII
DC
i
a
VI
n
IV
vm
V
VI
X
in
i
IV
vm
IV
VI
vm
i
in
X
ni
V
vm
Polye»t«r§
Number
Production Capacity
Units KXXg/yr
Alabama
Alaska
Arizona
Arkansas 1 23
California 18 140
Colorado
Connecticut 1 11
Delaware 1 11
Florida 6 87
Georgia
Hawaii
Idaho
Illinois 3 7
Indiana 2 21
Iowa
Kansas
Kentucky 1 5
Louisiana 1 10
Maine
Maryland
Massachusetts
Michigan 6 57
Minnesota
Mississippi
Missouri 3 42
Montana
Nebraska
Nevada
New Hampshire
New Jersey 5 44
New Mexico
New York 3 is
North Carolina 2 IS
North Dakota
Ohio 11 RB
Oklahoma i 14
Oregon i 2
Pennsylvania s IK
Rhode Island
South Carolina ? ?K
South Dakota
Tennessee 3 35
Texas 3 27
Utah
Vermont
Virginia
Washington 1 13
West Virginia
Wisconsin 1 18
Wyoming
TOTAL 81 725
Region I 1 11
n B ss
HI 6 47
IV 14 168
V 23 169
VI 6 74
VD 3 42
vni
DC 18 140
X 2 IS
Amino Resins'11 Alkyds'11
Number Number
Production Production.
Units Units
3
2
13
1
2
2
3
10
2
1
1
1
5
3
1
1
1
2
2
IS
t,
11
12
1i
11
5
1
8
3
6
8
164
16
23
17
31
33
11
i
1
13
18
1
30
2
1
4
3
23 ..
1
2
5
5
5
6
J
7
26
»
11
,
2
1?
j
1
10
1
3
179
S
35
19
IS
51
10
S
30
2
(i) Capacities not available for these resin*.
Source: Poster D. Snell, Inc. analysis of daca from:
(a) Systems Ar.alyti* at Air Pollutant Emissions from the Chemical '
Plastics Industry, U.S. Environmental
Protection Agency,
environmental Protection Technology Series EPA 650/2-74-106,
October, 1974.
(b) "Supply Status*, Modern Plastics, Vol. 52, No. 1, January, 1975
(c) 1974 Final Monthly Statistical Report
Plastic t Re tin Material*,
SPI etc., SPI Caemitta* on Ra«in Statistics a* compiled by
Ernst t Ernst.
(dl "Plastics I Rosins", Chemical Economic Handbook, Stu>far4
Research Institute
11-19
-------
TABLE H-5 (6)
Acrylics
Coumarone- Indent
and
Petroleum Resins
' ' '
Polvurethanes
*11
Number
Production Capacity
Units KKKa/vr
Number
Production
Units
Xuirber
Production
Units,
IV
Alabama
1
Alaska
IX
Arizona
VI
Arkansas
IX
California
28
VIP Colorado
i
Connecticut
m
Delaware
IV
Florida
IV Georgia
DC
Hawaii
Idaho
Illinois
1C
Indiana
VII Iowa
V£I Kansas
IV
Kentucky
VI
Louisiana
_8i.
i
Maine
HI Maryland
i
Massachusetts
Michigan
Minnesota
IV Mississippi
Vn Missouri
Vm Montana
VII Nebraska
IX Nevada
i
New Hampshire
VI
TV
New Jcrs?y_
New Mexico
New York
North Carolina
Vin North Dakota
Ohio
12
VI Oklahoma
Oregon
HI Pennsylvania
11
I
Rhode Island
IV
South Carolina
Vin South Dakota
IV
Tennessee
VI
Texas
4 337
VIII Utah
I
Vermont
111 Virginia
Washington
III
West Virginia
32
Wisconsin
VIO Wyoming
TOTAL
462
20
135
Region
I
II
III 1 32
IV 1 2
V
VI 5 428
vn
vni
rx
X
i
i
5
4
3
4
2
12
20
18
3
38
5
6
1
28
4
(1) Capacities not available for these resins.
Source; Foster 0. Snell, Inc. analysis of data from;
(a) Systems Analysis of Air Pollutant Emissions from the Chemical/
Plastics Industry, U.S. Environmental Protection Agency,
Environmental Protection Technology Series EPA 650/2-74-106,
October, 1974.
(b) "Supply Status", Modern Plastics, Vol. 52, No. 1, January, 1975
(c) 1974 Final Monthly Statistical Resort Plastic t Resin Materials.
SPI etc., SPI Cootittee on Basin Statistics as compiled by
Ernst S Ernst.
(d) "Plastics S Resins", Chemical,Economic Handbook. Stanford
Research Institute T T..L 0 0
-------
TABLE II-5 (7)
IV
\
IX
VI
IX
via
i
iii
IV
IV
IX
X
v
V
VII
VII
IV
VI
I
HI
I
v
v
rv
VII
VIII
VII
IX
i
ii
VI
n
R'
vm
Cellulosic
Resins t1' Epoxv Resins
Number Number
Production Production Capacity
Units Units KKKe/vr
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky 1 16
Louisiana
Maine
Maryland 1
Massachusetts i 1 K
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey 5 .1 41
New Mexico
New York
North Carolina
North Dakota ._. -
Polyamides
\umber
Production Capacity
Units KKKa'vr
1 11_
2 a
1 n a.
1 2
V Ohio 1 -6
VI
X
III
I
rv
vm
IV
VI
vm
i
in
X
in
v
vin
Oklahoma
Oregon - —
Pennsylvania
Rhode Island __
South Carolina
South Dakota __
Tennessee t ._ ._
Texas 2 63 —
Utah
Vermont —
Virginia -
Washington
West Virginia
Wisconsin
Wyoming
TOTAL 8 8 136
Resion 1116
— n 5 5 Is
III 1
IV 1 1 16
• V 1 6
VI i U —
vn
1 -1
1 1
1 n.a,
1 -----
1 32
10 62'
2 2*
3 40
4 20
vni
• • K
X
Source FoittrD. Snell, Inc. analyst of d«u horn
(1) Svitemi An»lyii« of Alt PolliKMt tmlulont from ihe ChenUol.TUrtci Induaiy. U.S.
Envltonmenul Protection Agency, Environment*! Pretecaon Technology Scriei EPA
6S0.2-H-106. October. 191*.
(b) Supply Sana'. Modem Plmlct. V0). 52, No. 1. Umury. 191S
,e) -.974 Fitul Monthly Suamcll tepon PUidc 3. tertn Mliep.U. SPletc.. SP1 Commtttee on
Benn Suuirlc! »i compiled tiy Emst t Emit.
(SI Pl«d«i !taln» . Chemicil Economic mndbook. Sunford teoich Iruotuie
11-21
-------
2.1.2 Geographic Distribution Of Employment
Table II-6 presents the estimated 1974
geographic distribution of employment as a function
of the number of production units. Information is
presented as an aggregate for the entire SIC 2821
since employement figures related to each of the
resins was not available.
There was a total of 56,450 employees
estimated to be working in the industry
on an average of approximately 70 employees
per production unit.
Employment was concentrated in the same
manner as production units and capacity
discussed under 2.1.1.
The following data provides an estimate of produc-
tion unit size distribution by employment on a
national basis for SIC 2821 as a whole.
Table II-7 — Production Unit Size Distribution By
Employment, SIC 2821 (National Basis)
Number of
Production
Units
816
1-4 5-9
10-
19
20-
49
50-
99
100-
249
38 38 76 232 139 167
250-
499
66
500-
999
35
1,000-
2,499
20
2,500
or more
From the above information, it can be seen
that the greatest number of production units (232)
have between 20-49 employees and account for 28% of
the industry. Most of the production units (66%)
are in the size range between 20-249 employees.
Only 3% of the production units have 1,000 employees
or more. Nineteen percent have fewer than 20
employees.
11-22
-------
TABLE II-6
ESTIMATED 1974 GEOGRAPHIC DISTRIBUTION
OF PLANTS AND EMPLOYMENT IN
SIC 2821
Total Number of
Production Units
IV
X
IX
VI
IX
vin
i
ni
IV
IV
IX
X
V
V
VII
VII
IV
VI
I
ni
i
V
V
IV
VII
VIII
VII
IX
I
II
VI
II
IV
vin
V
VI
X
III
I
IV
vin
IV
VI
vin
i
in
X
in
V
vin
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
n
UI
IV
V
VI
vn
vni
DC
X
a
3
114
3
7
3
IB
7
7
70
a
g
2
10
17
4
12
43
22
7
4
if
2
4
87
31
22
65
2
22
46
9
8
7
73
1
4
12
12
17
816
64
48
83
92
186
95
24
8
114
34
Employment
50
100
2200
50
1800
800
200
200
N.A.
4500
1800
350
350
2550
1800
200
5900 .
2550
7 SO
SO
200
N.A
200
Sinn
200,0
350
4SpO
150
inn
ssno •*
100
2QO
1800
4250
N.A.
100
100
4250
750
56.450
8000
T 7366
11.250
5400
14.850
8300
100
SO
2200
200
Source:
Snell update of data from the 1972 Census of Manufacturers, U.S.
Department of Commerce. Publication MC-72(2)-2IB.
11-23
-------
2.1.3 Distribution Of Plant Age
Distribution of plant age is not provided
for SIC 2821 due to the inavailability of data.
Most of the production units, however, were first
constructed after the Second World War with many of
the major ones being built in the late 1950's and
early 1960's.
2.1.4 Geographic Distribution Of Production
Volumes
Table II-8 is a summary of the geographic
distribution of production volume by production
unit for SIC 2821 as an aggregate for 1974.
Table II-9 presents the geographic distri-
bution of the estimated production volume of the
sixteen major SIC 2821 resins listed in Section 2.1.
From these tables, the following conclusions
can be drawn:
Over 12,000 KKKg of resins were estimated to
have been produced in 1974 by SIC 2821 pro
duction units.
The general concentration of production
units and production was identical with
that for capacities as shown in Table II-6.
For the entire SIC 2921 industry segment an
average of approximately 15 KKKg of material was
produced by each production unit in 1974. This
value reflects the fact that there are many units
producing only a small amount of resin. This is
particularly valid for the phenolics, alkyd and
polyurethane resins.
On the average, over 80% of the production
capacity for SIC 2821 was utilized in 1974. For
example, of the high volume resins:
Polyethylene was being produced at 93%
of capacity
Polystyrene was at 95% of capacity
Polypropylene at about 84% of capacity
Polyvinyl chloride was being produced at
75% of capacity.
11-24
-------
TABLE 11-8
ESTIMATED 1974 GEOGRAPHIC DISTRIBUTION OF
TOTAL PRODUCTION UNITS AND TOTAL
PRODUCTION , SIC 2821
Total Number of
Production Units
IV
X
IX
VI
tx
VIU
I
DI
IV
IV
IX
X
V
V
VIJ
VII
rv
VI
I
m
i
V
V
IV
VII
VIII
VII
IX
i
ii
VI
11
IV
VIU
V
VI
X
III
1
IV
vtn
IV
VI
VHI
I
III
X
III
V
vin
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
N'ew Hampshire
New Jersey_
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
n
UI
IV
V
VI
vn
vm
DC
X
8
3
114
3
7
9
16
7
70
8
6
2
20
17
1
12
43
22
4
4
16
2
4
87
31
22
65
2
22
46
9
a
7
73
1
4
u
12
17
816
64
118
83
92
186
95
24
6
114
34
Total
Production
(KKKg/yrl
29.4
18.0
696 9
4.4
154.4
296.8
117.0
12-4
945.2
119.4
212.8
13.0
149.4
1.430.0
2.0
91.2
665.5
178.6
4.6
24 0
115.5
40
7.4
610.1
246 7
86 0
1,033.7
82. 0
73.8
173 3
53 4
29 0
36.0
3.91S.O
2.0
13.0
40 8
317 8
72 2
12.078
881 .7
856 B
892 1
483 2
2.353.9
5.447.0
341.4
10.4
696.9
114.6
Source: Foster D. Snail. Inc.
11-25
-------
TABLE H-9 U>
GEOGRAPHIC DISTRIBUTION OF
PRODUCTION IN SIC 2821. PLASTIC
MATERIALS AND RESINS
Production — KKKq/yr
PVC
(11
PVAC
(21
PVA1
IV
X
IX
VI
IX
VID
I
ni
rv
IV
IX
X
V
V
VII
vn
IV
VI
i
m
i
V
V
IV
vn
VIII
VII
IX
i
I!
VI
II
IV
vin
V
VI
X
HI
I
IV
vin
IV
VI
VIII
I
HI
X
III
V
vin
Alabama
Alaska
Arizona
Arkansas
California 50
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois 310
Indiana 100
Iowa 75 133
Kansas
Kentucky
Louisiana 254 491
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
Xcrth Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas 965 1.640
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
91
181
41
104
93 7
265
68
180 35
223
100
260
74
61
,37,
315 23
.. 107
TOTAL
1.294
2.724
2.212
65
Region
217
35
II
UI
rv
V
VI 1
vn
.219
75
410
2.131
133
323
429
134
364
654
7
23
vni -
DC
50
9\
X
HDPE
LOPE
pv;
» High density Polyethylene
« Low Dens icy Polyethylene
• Polyvinyl cnloride
PVAC •
PVA »
< Polyvinyl Acetate
Polyvinyl Alcohol
(1) Production figures based on data froo th« 1974 Final Monthly Statistical
Report, Plastic i. Resin Material!, SPI Cooutt** on RMin statistics a*
compiled by Ernst 4 Ernst, March 21, 1975, and pro rated according Co
capacity.
(2) Production data is not conparable to that of other reiins u it i*
expressed in terms of the nonoMr.
11-26
-------
TABLE IJ-9 (2)
Production -- KKKa/vr
iv
X
IX
VI
IX
VIII
I
III
IV
IV
IX
X
V
V
VII
VII
IV
VI
1
ni
i
V
V
rv
vn
VIII
VII
IX
i
ii
V!
11
IV
VIII
V
VI
X
III
I
IV
vin
rv
VI
VIII
i
in
X
ill
V
vin
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hauar,
Idaho
Illinois
Indiana
low a
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
Nor:;-. Dakota
Ohio
Oklahoma
Oregon
Per.n?v!van;a
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
n
ni
IV
V
VI
vn
vni
DC
X
ABS-3AN - Acrylonitrile-
No'es :
••1)
?r;xju<:tion figures
Report, Plastic £ R
Phenolics
and
Other Tar
ABS-SAN1" Polystyrene'11 Polypropylene '" Acid Resins !1
13
7 300 58
23 119 4
97
4
89 343 J
13
11
3* 266
376 34
37 76 13
7?
2
12 ins «
ins
14 - . 31
96 454 124
in
66 491 53
18
93 63
38
440 1.844 1.026 610
23 495 38
12 106 181
93 160
11 14 48
222 873 17S
72 86 760 52
76 13
2
7 300 58
59
Butadiene~Styren« Resins and Styr«ne-Acrylonitrile
based on data from the I""1* Final monthly Statistical
esin Materials, SPI Comnittee an Resin Statistics as
compiled by Ernst & Ernst. March 21* 1975, and pro rated According to
capacity.
11-27
-------
TABLE n-9 (3)
Production — KKKq/yr
rv
X
IX
VI
IX
vin
i
iii
IV
IV
IX
X
V
V
VII
VII
TV
VI
1
m
i
V
V
IV
VII
VIII
VII
IX
I
II
VI
II
IV
VIII
V
VI
X
III
I
IV
vin
IV
VI
VIII
1
III
X
III
V
vm
Notes
(1)
(2)
. (3)
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
II
HI
IV
V
VI
vn
vm
DC
X
Polvesters'1'
13
«2
«
?
51
4
n
3
6
33
24
25
•
8
39
8
20
15
20
15
7
9
415
6
33
26
97
97
42
24
82
8
Production figures based on data
Report, Plastic & Resin Materials
compiled by Ernst &
capacity.
Production figures
Emissions from the
Ernst, March
based on data
Coumarone-
Indene
and
Amino Petroleum
Resins <2> A*lkyds Acrylics'3' Hesins<2'
7 2
5
31 52
4
2
5 2
5 7
7 S
23 40
7
4
5 9 1
2 59
2
2 9
S 3
7 11
4
2
2 12
2
s
42 Af
12 IS
33
28 23
28 4
26 23
16
12 2
2 2
19 17 22B
2
7
H
21
19 5
377 317 301
30 9
S« 62
40 34 21
73 27 1
77 90
26 17 279
2 16
2 1
31 52
42 4
7
15
22
IS
7
22
7
31
IS
7
148
7
7
38
29
22
30
15
fron the 1974 Final Monthly Statistical
j_ SPI Cooaittee on Resin Statistics ai
21, 1975, and pro rated according to
from System Analysis of Air Pollutant
i
Chemical/Plastics Industry, U.S. Environmental
Protection Technology series EPA
pro rated according to production
Data from above but pro rated by
650/2-74-106, October, 1974, and
unit distribution.
capacity.
11-28
-------
TABLE
(4)
Production — KKKg/yr
Poly- Cellulosic Epoxy
urethanesul Resins*1' Resins Polyamides11
IV Alabama
0.4
X Alaska
IX Arizona
VI Arkansas
IX California
Vin Colorado
I Connecticut
ni Delaware
IV Florida
IV Georgia
10.9
0.4
0.4
0.8
9
0.4
IX Hawaii
X Idaho
V IlJinois
V Indiana
Vll Iowa
6.2
0.4
0.8
VII Kansas
tV Kentucky
VI Louisiana
0.4 13 7
I Maine
nt Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIH Montana
1.2 11
3.5 11 5 n.a
1.6
0.8
1.6 . .
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
0.4 2
5.1 54 37 _
2.7
Vin North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
4.7 5
a a . ... ..
43 0 1
n 4
Vin South Dakota
IV Tennessee
VI Texas
it i
2.0 S3 Jl_a_._ .,
VIH Utah
[ Vermont
in Virginia
X Washineton
III West Virginia
V K:sconsin
Vin Wyoming
TOTAL
Region I
- " 11
111
IV
V
VI
vn
vni
DC
X
Notes:
(1) Production figures
Emissions from the
Agency, Eiwironnen
October, 19">4, and
(2) Production figure*
Report, Plastic &
compiled by Ernst
capacity.
R
O.B
n R ?K
12 . -
53 87 113 52-
47 11 5 2*
78 54 37
7.1 11 33
12 11 13 17_
149 i_
2.0 S3 n a.
24
04
10-1
IS
based on data froa System Analysis of Air Pollutant
Chemical/Plastics Industry, U.S. Environmental Protection
tal Prot«ction Technology series EP» 650/J-74-106,
pro ratad according to production unit distribution.
based on data from the 1974 Final Monthly Statistical
Resin Materials, SPI Coniittee on Resin Statistic! a*
t Ernst, March 21, 1975, and pro rated according to
11-29
-------
For typical lower volume resins, the
following are estimates of capacity utilization for
1974:
ABS/SAN -- 78%
Polyesters — 57%
Acrylics — 65%
Epoxy — 83%
2.2 Structure Of The Synthetic Rubber (Vulcanizable
Elastomers) Industry, SIC 2822
For this industry in 1972, value added by manufac-
turers was $491.7 million according to the 1972 Census
of Manufacturers, while value of shipments was $1,089.4.
There were over 11,000 employees working in SIC 2822 in
1972.
The products of this industry are principally used
in five segments of the U.S. economy: new tire production,
tire retreading, molded rubber goods, footwear and ad-
hesives. In 1973 about 65% of synthetic rubber production
went into the production of new tires.
There are approximately 50 different types or
classes of synthetic rubber or Vulcanizable elastomers.
Of these 50, nine are most important on a weight of
production basis. These nine synthetic rubbers are, in
decreasing order of importance, as follows:
Styrene-Butadiene Rubber (SBR)
Polyurethanes
Polybutadience
Acrylics
Neoprene
Butyl rubber
Ethylene-propylene co- and ter- polymers
(EPM and EPDM)
Isoprene
Silicone.
In general, this report focuses on the above nine
elastomers since they represent over 95% of SIC 2822's
production.
Appendix A presents the detailed methodology used
in developing the data presented in the tables for this
industry.
11-30
-------
2.2.1 Geographic Distribution Of Plants And
Production In SIC 2822
Table 11-10 presents a summary of the geo-
graphic distribution of production units and their
estimated 1974 production for this industry segment
as an aggregate.
Table 11-11 presents the geographic distri-
bution of production units and their estimated 1974
production on a product by product basis.
Our survey has found that there are approx-
imately 120 production units within SIC 2822.
The synthetic rubber industry is very
heavily concentrated in the Gulf Coast area
in such states as Texas and Louisianna,
with a smaller grouping in Ohio and Kentucky
and minor installations to Connecticut and
Tennessee.
Of all the rubbers produced by SIC 2822,
the greatest production in 1974 was of SBR type
rubber and is estimated to be 2,116 KKKg. This
value was on the order of almost four times the
production for these next highest synthetic rubbers
produced—acrylates, polyurethane and polybutadiene.
2.2.2 Geographic Distribution Of Employment
Table 11-12 presents the estimated 1974 geo-
graphic distribution of employment. Information is
presented as an aggregate for the entire SIC 2822
since employment figures related to each of the
rubbers is not available.
There was a total of about 17,000 employees
estimated to be working in the industry.
Employment was concentrated in the Gulf
Coast (Texas and Louisianna) area with a
smaller but sizeable grouping in the Ohio/
Kentucky area.
The distribution of employment reflects the location
of the plants near their suppliers of monomers
(Gulf Coast) or their location near the major tire
plants where about 65% of the production from
SIC 2822 is used.
11-31
-------
TABLE 11-10
SUMMARY OF GEOGRAPHIC DISTRIBUTION
Or PRODUCTION UNITS AND ESTIMATED
19"M PRODUCTION, SIC 2822
Number of
Production Units Production (KKKg/yr)
IV
X
IX
VI
tx
VIII
r
in
IV
IV
rx
X
V
V
VII
VII
IV
VI
I
III
I
V
V
IV
VII
'/III
VII
IX
I
II
VI
II
IV
VIII
V
VI
X
III
I
IV
VIII
IV
VI
VIII
I
III
X
III
V
VIII
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michioan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Otah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
II
III
IV
V
VI
1
5
7
1
3
5
6
15
4
4
1
1
/
3
2
14
1
2
32
6
120
12
a
9
15
24
50
0.05
40.5'D
11I.O<*>
20.0
30.0
294.5111
347.7
923. S
20.0<1>
69.3
0.05
4.5
71.0f2>
4.15D
24,0 _
770.2
20.0
60.0
2130.2
452.6
5393.5
131.0
75.1
492.6
466.3
1134.1
3054.0
VII
VIII
IX
3
40.5
X
notes.-
(1) Production figures Cor one unit are not available.
(2) Production figures for two units are not available.
Source: Foster D. Snell, Inc.
11-32
-------
TABLE 11-11 (1)
ESTIMATED 1974 GEOGRAPHIC DISTRIBUTION OF
SYNTHETIC RUBBER PRODUCTION
rv
X
IX
VI
IX
vin
i
UI
IV
IV
IX
X
V
V
VII
VII
rv
VI
i
DI
1
V
V
IV
VII
VIII
VII
IX
I
II
VI
II
IV
VIII
V
VI
X
III
I
rv
vm
rv
VI
vin
i
in
X
in
V
vin
Acrylates
No. of Production
Plants U) KKJCg/yr
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana 1 90.8
M ^ : n e
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mex.co
New York
North Carclir.a
Nor:h Dakota
Ohio
Oklahoma
Ores on
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas 4 336
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL 5 42S.8
Region 1
Acrylonitrile
Acrylic Rubbers Butadiene Rubbers
No. ol Production No. ol Production
Plants'1' KKKg /yr Plants'1) KKXg/yr
1 N A 12)
1 N.A
2 18.2
2 65
1 N.A. 1 5
1 N A
1 1.5 4 6T
1 11
S 1.5* 10 166 2
2 N.A. 1 5
n i N.A.
UI
rv
V
VI 5 426. S
vn
1 N.A. 2 16 2
1 1.5 4 67
3 76
vni
DC
X
Notes:
7T) This indicates th« maiber of plants in a given state which produce the
given typ« of rubber. In some instances that type is not the pri»«ry
product. It «ay also indicate captive production.
(2) N.A. - not available.
Sourc«; roster D. Snell, Inc. analysis of "Chemical Profiles' Oil, Paint t
Drug Reporter; Ruebensaal's The Rubber Industry Statistical Report
11-33
-------
TABLE II-11 (2)
ABS Resins
Butadiene Styrene
Copolymers
Polybutadienes
rv
X
IX
VI
IX
vin
i
m
IV
rv
K
X
V
V
VII
vn
IV
VI
No . of Production
Plant* (1) KKKg/yr
Alabama
Alaska
Arizona
Arkansas
California 1 20
Colorado
Connecticut 1 65
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois 2 260
Indiana
Iowa
Kansas
Kentucky
Louisiana
No. Of Production No. Of Production
Plants (1) KXg/yr Plants'" nocg/yr
2 16.5
3 42
1 20
2 30
1 7.5 1
2 132. S 1
3 446.5
7
75
1 Maine
m
I
V
V
IV
vn
vm
VTI
IX
i
u
VI
II
IV
VIII
V
VI
X
III
1
TV
vin
:v
VI
vm
Maryland
Massachusetts
Michigan 1 60
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
Xew York
Ncrth Carolina
North Dakota
Ohio 1 275
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
L'tah
2 15
1 4
1 1.4
2 2J
3 367
1 20
2 60
9 930 S
395
I Vermont
111
X
m
V
vin
Virginia
Washington
West Virginia 1 290
Wisconsin
Wvomine
TOTA.L 7 S90
Region I 1 85
- n
HI 1 290
rv
V 4 61S
VI
vn
35 2116.4 10
S 57
1 1.4
2 40
6 246.5 I
5 376.5 1
U 1376.5 6
477
75
7
sis
vni
K 1 Z»
X
16.5
Mote:
IT)This indicates the nusfcer of plant* in a givm state which produce the
giw«n type of rubber. In sea* instance* that type is not the primary
product. It Bay also indicate captive production.
source: ro»ter D. Siwll, Inc. aaalysi* of *Che*ical Profiles' Oil. Faint t
Drug Reporter; Ruebenaaal• • The Rubber Industry Statittical Uport
11-34
-------
rv
TABLE II-ll U>
Butyl Rubber
Chlnro5Ulfonated
Polyethylene (Hypalonl
E-P Elastomers
Alabama
No . of Production
Plants(1) KXKg/yr_
No. of Production No of Production
Plants!!) KKXg/yr Plants U> KKXg/yr
Alaska
IX
Arizona
VI
Arkansas
IX
California
VID Colorado
I
Connecticut
III
Delaware
rv
Florida
IV Georgia
IX
Hawaii
Idaho
Indiana
Vll
rv
Iowa
Kansas
Kentuckv
vi_
i
Louisiana
86. 5
88
Maine
m
i
v
V
rv
Vll
vin
vn
ix
i
ii
VI
IJ
rv
vm
v
VI
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
v
ill
I
vm
iv
VI
VI11
I
in
x
in
New Mexico
New York
North Carcl;r,a
North Dakota
Ohio
Oklahoma
Oregon
Penns
Rhode island
Carohna
South Dakota
Tennessee
Texas
Utah
Vermont
Washington
West Virginia
21.
-- -
77 8
TOTAL
162.5
21.5
165 8
Region
I
— n " ~IIZ__ . ,
11 T
rv . . .
VI "3 162.5 1 215 5 165.8
VD —
ym — — —
IX — — —
X - — — _— _
Note:
(1)
This indicates the number of plants in a given state which produce the
given type of rubber. Ir, some instances that type is not th« primary
product. It nay also indicate captive production.
D Snell, inc. analysis of "Chemical Profiles" 3il, Faint i.
:porter; Ruebensa,,: ' s The Rubber Industry Statistical Report
Foster
Drug Repo:
u-35
-------
TABLE Il-ll (4)
IV
X
IX
V!
IX
VIII
J
ni
rv
iv
IX
X
V
V
VII
VII
IV
VI
I
ni
i
V
V
IV
VII
vm
VII
IX
i
ii
VI
1)
IV
VID
V
VI
X
111
EpicMorohydrin
E. - -tomers Fluoro Rubbers
No of Production No . of Production
Plants (11 wocg/yr Plants'1) K«g/yr
Alabama 1 0.05
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentuckv
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota 1 0.05
Mississippi I 4.5
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey 1 0.4
New Mexico
New York
North Carolina
\orth Dakota
Ohio l 4.5
Oklahoma
Oregon
Pennsylvania
Isocyanate
Type Rubbers
No . of Production
Plants'1) KJOCg/v:
3 112
1 46
1 16 :
I Rhode Island
IV
vin
IV
VI
vin
i
in
X
ni
V
vin
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL 2 9 3 0.5
3 152
3 154 3
11 484 5
Region 1
1J I 0.4
III
1 48
3 1543
IV 1 4.5 1 0.05
VI 4.5 1 0.05
VI
1 18 :
E 264
vn
vm
K
X
Note:
(1) This indicates the number of plants in a given st»te which produce the
given type of rubber. In scmw instances that type is not the primary
product. It may also indicate captive production.
Source: Foster D. Snell, Inc. analysis of "Chemical Profile*' Oil. Paint f.
Drug Reporter; Ruebensaal ' s Trie Rubber Industry Statistical Report
11-36
-------
TABLE 11-11 (5)
IV
Isoprene Rubber
Synthetic
No. oif Production
Neoprene
No. 67Production No. ol Production
Polysulfides
Alabama
1NO. OI Production NO. 01 production «u - ui rroauctiun
Plants!1) KKKg/yr Plants!!) KKKg/yr Plants"* KKKg/yr
Alaska
IX
Arizona
VI
IX
Arkansas
California
VIII Colorado
Connecticut
III
Delaware
rv_
IV
IX
X
V
V
Vll
VII
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentui-kv
122
VI
I
III
I
V
V
IV
VII
VI11
VII
IX
1
n
VJ
II
rv
vm
V
VI
x^
111
I
rv
vm
rv
vi
VIII
i
m
x
111
v
vm
Louisiana
Maine
35
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
9.1
New York
North Carolina
North Dakota
Ohio
32
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
107.3
_2fl_
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
141.5
177
9.1
Region
in
vn
V i
VI 2
32
107.3
2
55
vni
DC
Note:
(1)
"This indicates the number of plants in a given state which produce the
given type of rubber. In some instances that type is not the primary
product. It may also indicate captive production.
Source: Foster D. Snell, Inc. analysis of "Chemical Profiles" oil, Paint i.
Drug Reporter; Ruebensaal's The Rubber Industry Statistical Report
11-37
-------
TABLE 11-11 (6)
Urethane Rubber Vulcani^-d Oils
rv
No . Of Production
Plants'1' KKKg/yr
No of Production No. of Production
Plants'" KKKq/vr Plants'" KKKg/yr
X Ala.-krf
IX
VI
IX
VIII
1
111
rv
IV
IX
X
V
V
VII
VII
a'
VI
i
in
i
V
V
IV
VII
VIII
VII
IX
i
n
VI
n
IV
VIII
V
VI
X
III
[
n'
vin
IV
VI
VIII
i
HI
X
III
v
vin
Arizona
Arkans-as
California 1 4
Colorado
Connecticut 1 4
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kenfickv
Louisiana
Maine
Mar viand
Massachusetts
Michigan 2 5.3
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey 1 9-1
New Mexico
New York 1 2.7
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washineton
West Virginia 1 1.5
Wisconsin
Wyoming
TOTAL 7 28.6
Region 11 4
n 2 11.8
HI l 1.5
IV
V 2 5.3
VI
vn
1 N.A.
1 N.A.
.
1 N.A.
1/3 2.2/N.A. 1 N.A.
1 N.A.
2 S
1 36
1
5/7 17.6/N.A 1 N.A
1 N.A. 1 N A
1/4 22/N.A.
1 6.8
2/1 S/N.A.
1 3.6
vm
DC 1 «
X
1 N.A.
Notes: (1) This Indicates the number of plants in a given state which produce the given
type of rubber. In some instances that type is not the primary product.
It may also indicate captive production.
121 N.A. - not available.
Source: Foster D. Snell, Inc. analysis of "Chemical Profiles" Oil. Paint 6 Drug
Reporter; Huebensaal's The Rubber Industry Statistical Report
11-38
-------
TABLE II- 14 '
ESTIMATED PLANT AGE DISTRIBUTION OF
STYRENE-BUTADIENE SYNTHETIC
RUBBER PRODUCTION UNITS
IV
X
IX
VI
IX
vm
i
ni
rv
IV
LX
X
V
V
VII
VII
IV
VI
I
DI
I
V
V
IV
VII
VIII
VII
IX
I
II
VI
n
rv
mi
V
VI
x
in
i
IV
vin
IV
VI
VIII
I
III
X
III
\J
vm
Number of
Production 0-9
Units Years
Alabama
Alaska
Arizona
Arkansas
California 2 1
Colorado
Connecticut 3
Delaware I
Florida
Georgia 2 2
Hawaii
Idaho
Illinois 1
Indiana
Iowa
Kansas
Kentucky 2 1
Louisiana 3 1
Maine
Maryland
Massachusetts 2 1
Michigan 1
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York !
North Carolina 2 1
N'ortfi Dakota
Ohio 3
Oklahoma
Oreeoi:
Pennsylvania 1
Rhode Island
South Carolina
South Dakota
Tennessee 2 1
Texas 9 2
Utah
Verrr.ont
Vireima
Washirj?ton
West Virginia
Wisconsin
Wyoming
TOTAL 35 10
Region I 5 1
II 1
III 2
IV 8 5
5
VII
VIII
IX 2 1
_x
Plant ABB
10-19 20-29 30*
Years Years Years
1
2 1
1
1
1
2
1
1
1
1
3
1
1
l 1 5
8 4 13
3 1
" t
11 ._
2 1 . . .
1 4
117
3 4 '-
_ — . .
Source: Rubber Red Book (1975). OPD Chemical Profiles. Rueben.aal'., The Rubber
Industry Statistical Report and Fo»ter D. SnelJ. Inc. estimates
11-41
-------
TABLE H- IS
ESTIMATED PLANT AGE DISTRIBUTION OF
POLYBUTADIENE PRODUCTION UNITS
of
Plant A«e
Production 0-9 JO-19 20-29 30*
Units Years Years Years Years N.A.
IV Alabama
X Alaska
IX Arizona
VI Arkansas ]
K California
Vin Colorado
1 Connecticut ,
HI Delaware
IV Florida
IV Georgia
DC Hawaii
X Idaho
V Illinois 1_ 1
V Indiana
VII Iowa
VII Kansas
IV Kentucky 1 1
VI Louisiana
1 Maine
03 Maryland
1 Massachusetts
V Michigan ..
V Minnesota
IV Mississippi
Vn Missouri
V1U Montana
VII Nebraska
IX Nevada
I New Hampshire
11 New Jersey
VI New Mexico
D Sew York
P.' North Carolina
VID North Dakota
V Ohio
VI Oklahoma
Oregon
III Pennsylvania
Rhode Island
IV South Carolina
VIH South Dakota
IV Tennessee
VI Texas
Vin Utah
I Vermont
111 Virginia
Washington
111 West Virginia
Wisconsin
VIP Wyoming
TOTAL 10
Region
II
111
IV
V
VI
1 1
1
8 1 5
1
2
VD
vni
K
X
N.A. * Not Available
Source: Rubber Red Book (1975). OPD Chemical Profiles. Huebensaal's. The Rubber
Industry Statistical Report and Foster D. Snell. Inc. estimates
11-42
-------
TABLE 11-16
ESTIMATED PLANT AGE DISTRIBUTION OF
ACRYLONITRILE-BUTADIENE SYNTHETIC
RUBBER PRODUCTION UNITS
Number of _____
Production 0-9
Units Years
Plant Age
10-19
Years
20-29 30-
Years Years
rv_
x
IX
V!
Alabama
Alaska
Arizona
Arkansas
California
VID
1
ni
rv
iv
ix
X
V
V
vn
yu
iv
VI
I
ni
i
v
V
rv
vn
VIU
Vll
IX
1
n
VI
II
rv
vin
v
vi
X
in
i
rv
V1D
rv
vi
VIII
I
HI
X
III
V
vin
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mex:co
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyomine
TOTAL
10
Region
n
in
IV
V
VI
2 1
4 3
3 1
1
1
2
vn
vni
K
X
Source: Rubber Red Book (1975). OPE Chemical Profiles. Ruebensaal's. The Rubber
Industry Statistical Report and Foster D. Snell. Inc estimate*.
11-43
-------
TABLE D-17
ESTIMATED PLANT AGE DISTRIBUTION
OF NEOPRENE PRODUCTION UNITS
Number of
Production
Units
Plant Age
0-9
Years
10-19
Years
20-29
Years
30*
Yews
IV
X
IX
VI
DC
vin
i
ni
jv
rv
rx
x
V
V
VII
vn
iv
vi
i
HI
I
V
V
IV
vn
vm
vn
ix
i
u
vi
u
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georq.a
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missour:
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mex:co
New York
Sen.*-. Carolina
vin
v
vi
X
in
i
iv
V1D
IV
VI
VIII
Nor'..*-, Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
IJJ
X
ni
V
vin
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region
ni
vn
vm
rx
Source: Rubber Red Book (197S), OPD Chemical Profiles. RuebencMl's. The Rubber
Industry Statistical Report and Foster D. Snell. IDC. estimate*.
11-44
-------
TABLE H-18
ESTIMATED PLANT AGE DISTRIBUTION OF
BUTYL RUBBER PRODUCTION UNITS
IV
X
IX
VI
IX
VIII
I
Ul
rv
IV
IX
X
V
V
VII
VII
rv
VI
i
ni
i
V
V
rv
VII
VIII
VII
IX
i
ii
VI
n
rv
vin
V
VI
X
HI
1
IV
vin
IV
VI
VIII
i
in
X
ITI
V
vm
Number of Plant Age
Production 0-9 10-19 20-29
Units_ Years Years Years
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louis:ana 3 i
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
M:ssour:
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New Ysrk
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Islard
South Carolina
South Dakota
Tennessee
Texas 1
Utah
Vermont
Virginia
Washington
West Virgin. a
Wisconsin
Wyoming
TOTAL 3 1
Region I
n
30-
Year s
1
1
2
ni
IV
V
VI 3 I
2
VD
vni
IX
X
Source. Rubber Red Book (1875). OPD Chemical Profiles . Ruebensaal's, The Rubber
~ industry Statistical Report and Foster D Snell. Inc . estimate*.
11-45
-------
TABLE 0-19
ESTIMATED PLANT DISTRIBUTION Of
ETHYLENE-PROPYLEN1 ELASTOMER
PRODUCTION UNITS
Number of
Production
Units
Fl«ni Age
0-9
Years
jn-19
Years
20-29
Years
3H
Years
IV
X
IX
VI
IX
VID
I
DI
IV
IV
IX
X
V
V
Vll
VII
IV
VI
1
ni
i
v
V
IV
VII
VIII
VII
IX
1
IJ
VI
II
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Marvland
Massachusetts
Michigan
Minnesota
Mississippi
Montana
Nebraska
Nevada
N'ew Hampshire
New Jersey
New Mexico
New York
North Carolina
VID
V
VI
X
HI
I
rv
VID
IV
VI
VIII
I
in
X
III
y
vin
North Dakota
Ohio
Oklahoma
Oregcr.
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region
n —
in
rv
V
VI 5
2 3
VD
vni
rx
X
Source: Rubber Red Book (1875). OPD Chemical Profiles. Ruebensaal's, The Rubber
Industry Statistical Report and Foster D. Snell, Inc. estimates.
11-46
-------
TABLE II-JO
ESTIMATED PLANT AGE DISTRIBUTION OF
ISOPRENE ELASTOMER PRODUCTION UNITS
Number of
Production
Units
Plant Age
0-9
Years
10-19
Yaars
20-29
Years
30+
Year*
N.A.
IV
X
IX
VI
IX
vin
i
ni
n/
iv
a
x
y
v
vn
vn
iv
VI
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
V
V
IV
vn
Vlll
vn
ix
i
n
VI
n
rv
vm
v
vi
X
in
i
rv
vm
iv
vi
Vlll
I
III
X
ni
v
VID
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
N'ew Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Or
egon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
n — i
1
in
IV
V 1 1
VI 1 1
1
vn
vm
DC
X
N.A. <= Not Available.
Source: Rubber Red Book (1975). OPD Chemical Profile*. RuabiniaaT*. The Rubber
Industry Statistical Report and Potter D. Snell. Inc. e«tiin«te«.
11-47
-------
TABLE 11-21
TOTAL ESTIMATED PLANT AGE
DISTRIBUTION OF PRODUCTION
UNITS FOR MAJOR SYNTHETIC
RUBBERS. SIC 2122
rv
X
IX
VI
rx
vin
i
ni
rv
rv
a
X
V
V
VII
vn
IV
VI
i
ni
i
V
V
IV
vn
vm
VII
IX
i
ii
VI
I!
ft-
vin
V
VI
X
III
Numl
Prod
Un
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentuckv
Louisiana
Main e
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey-
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
JBT of Plant ^fee
uction 0-9 10-19 20-29 Ov«r
its Yr* Yr» Yr« 30 Yr* N.A
211
3 2 1
1 1
2 2
2 11
621 3
11 4 3 4
312
1 1
1 1
1 1
2 1 1
e 44
1 1
I Rhode Island
rv
VID
rv
VI
vm
South Carolina
South Dakota
Tennessee
Texas
Utah
211
24 67 1 73
I Vermont
III
X
III
V
vm
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
n
ni
rv
V
VI
70 U 23 4 20 5
614 1
2 1 1
2 1 1
12 6 3 3
11 4151
35 10 10 1 11 3
VD
vni
DC
2 1 1
X
N.A.
- Not Available.
Source: Rubber ted Book (1975). OPO Chemical Profiles, RuebencMl'i.
The Rubber Industry St»ti»tic»l Report end Foster C. Snell. Inc.
estimates.
11-48
-------
Eighteen of the production units are in
the range of 0-9 years old.
Twenty-three are between 10-19 years old.
Only four are 20-29 years old.
Twenty are over 30 years old.
2.3 Structure Of The Man-Made Fiber Industry, SICs 2823
And 2824
This sub-section discusses the industry structure
for both fiber producing segments of the plastics materials
and synthetics industry.
SIC 2823, Cellulosic Man-Made Fibers
SIC 2824, Man-Made Fibers, Non-Cellulosic.
For the man-made fiber industry, the value added by
manufacture was $2,283.8 million according to the 1972
Census of Manufacturers, while the value of shipments was
$4,229.3 million. There were over 95 thousand employees
working in this industry in 1972. The split between
SICs 2823 and 2824 for these values were as follows:
For SIC 2823, the value added by manufacture
was $252.7 million, value of shipments was
$627.9 million and employment was 19,000 total
workers.
For SIC 2824, the value added by manufacture
was $2,031.1 million, the value of shipments
was $3,601.4 million and employment totalled
76,300 workers.
From these figures, it is apparent that the cellulosic
fiber industry is significantly smaller than the non-
cellulosic segment of SIC 282. In fact, SIC 2823 is the
smallest segment of SIC 282 in terms of employment, value
added by manufacture, value of shipments, number of
establishments and production volume on a weight basis.
The non-cellulosic fiber industry, SIC 2824 is exceeded
in the above terms within SIC 282 only by the plastic
materials and resins group, SIC 2821.
11-49
-------
The products of the fiber industry find use through-
out the U.S. economy. For example,, major end-uses of
cellulosic and non-cellulosic fibers are listed below
in order of product mix importance, d)
Broad woven goods: 43%
Flat knit goods: 15%
Non-woven goods: 12%
Tires: 6%
All of these end-uses are important in the economy.
There are two important cellulosic fiber classes
produced by SIC 2823:
Rayon
Acetates and triacetates
and four important non-cellulosic fiber classes produced
by SIC 2824:
Polyesters
Nylon and aramids
Acrylics and modacrylics
Polyolefins and vinyon.
In general, this report focuses on the above listed
cellulosic and non-cellulosic fibers. These materials
represent over 95% of production in SICs 2823 and 2824.
(1) Foster D. Snell, Inc., Industrial Energy Study Of The
Plastics And Rubber Industries, SICs 282 and 30. Contract
Number: 14-01-0001-1655, U.S. Department of Interior,
Bureau of Mines, Washington, D.C. (1974).
11-50
-------
2.3.1 Geographic Distribution Of Production Units
And Employment, Man-Made Fiber Industries,
SICs 2823 And 2824
Table 11-22 presents the estimated 1974
geographic distribution of production units and
employment for the man-made fiber industries.
Our survey has found that there are approxi-
mately 166 production units within these
industries.
The cellulosic and non-cellulosic fiber
industries are both concentrated in the
South Atlantic states near the large textile
mills. These states of high concentration
include Tennessee, North Carolina, South
Carolina and Virginia.
Employment values are given as an aggregate for
both SICs comprising the fiber industry. This
approach was taken because in many cases there are
several production units at one site and in some
instances these units are in both SICs 2823 and
2824.
2.3.2 Plant Age Distribution
Estimated plant age distributions for the
fiber groups of SIC 282 were developed with the
assistance of the Textile Economics Bureau.
2.3.2.1 Cellulosic Man-Made Fiber Industry,
SIC 2823
Table 11-23 presents the estimated
production unit age distribution for this
industry. The majority of production units
(10 out of 13 still in production) are over
30 years of age. One production unit is in
the range of 10 to 20 years old and the
remaining two began production 20 to 30
years ago.
11-51
-------
TABLED-22
ESTIMATED 1974 GEOGRAPHIC
DISTRIBUTION OF PRODUCTION
UNITS AND EMPLOYMENT - SIC« 282 J AND 2824
rv
X
IX
VI
IX
VID
I
DI
rv
rv
IX
X
V
V
VII
VII
rv
VI
i
m
i
V
V
Mamsade Fibers Mcnnad* Fibers
Cellulouc Noo-Catlulocic
SIC M23 SIC 2824
:| I* II Is s
1 ll i! If i! 1
*
3.000
IB 3 000
3.000
(D!
ID,
(DI
IS 3.000
_..iX . ID)
ID!
[0!
rv M:S?:SS:PP:
Vt!
VII!
VII
IX
I
II
VI
II
rv
vin
V
VI
X
SII
i
rv
vin
IV
VI
VIII
Missouri 2
Montana
Nebraska
Nevada
New Hampshire
New Jersey 3
New Vex;co
Neu lork 1 3 U
\rr-..- Carolina 4 4 1
North Dakota
Ohio 1 1
OK.ahotra
Oregor.
Per.nsvivan.a 1 1 2 'IV 1
Rhod* island 1
South Carohna 1 iq 1 3 10
South Dakota
Tennessee 2 1 « 1M 5 5
Tex ax
Utah
ID-
'S irij
IF tD
IX 13 OOC
.D
3 OOC
(D>
IB 18.000
15.000
(DI
I Vermont
111
X
m
V
vin
Virginia 2 2 6 1A 2 3 4
Washington J
WestVirg:n:a 11 l
Wisconsin l
WyominR
TOTAL 6 7 38 6 60 39
Region I 5
- U 1 71
III 3 4 11 2 10 8
IV 3 3 25 4 26 29
V 4 1
VI 2
vn i 3
3FXP 15.000
ID.
3.000
(Dl
10 105.000
1 3 000
2 S~. 000
4 27.000
3 60.000
3.000
(D)
3.000
vm
IX 2
X 1
(D)
(D)
(1) Employment is total for both SIC 2823 «nd 2824 Is in many cases there are several
production units at one site and in same instances these units are in both SICs.
(2) (D) - d»u not presentad to avoid disclosure-
Key
A - Aramid P - Polycarbonate SIC 2823 * Cellulosic Manmade
B - Biconstituent S - Sarin Fiber Industry
F - Fluoroc«rbon V - Vlnyon SIC 2824 - Non-Cellulosic Manmade
M - Modacrylic X - Spandex '«b«r Industry
Source Textile Organon. Sept 1975. Snail analysis of information supplied by the
Textile Economics Bureau and 1972 Census of Manufacturers. U.S. Department
of Commerce Publication No MrT?r^i.»»s
11-52
-------
TABLE II- :;
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLANT AGE
CELLl'LOSIC MAVVADE FIBERS
SIC 2623
Tola! Plant Agf (Years!
No. o'. ~5 or ~~
FlanU Le«v i-10 10-20 20-3C 30 or n-.orc
Alat
-------
2.3.2.2 Non-Cellulosic Man-Made Fiber
Industry, SIC 2824
Estimated production unit age
distribution for this industry are presented
in Table 11-24.
As can be seen from a comparison
of Tables 11-23 and 11-24, SIC 2824 is a
newer industry than SIC 2823. A summary of
production unit ages is provided below.
Table 11-25 — Summary Of Ages Of Production Units,
~SIC 2824'"
Total Number of
Production Units
Identified
153
Production Unit Age (Years)
4 or
Less
52
5-9
46
10-19
40
30 or
More
Source: Foster D. Snell, Inc.
Over 66% of the production units
are between less than 5 years old to 10
years in age. Only approximately 3% are
thirty years old or more.
The oldest units are generally
those producing nylon and spandex. The
newest production units are those manufac-
turing polyolefins, polyesters and some
small volume fibers such as fluorocarbons
and polycarbonates.
Table 11-26 through 11-30 present
production unit ages of the individual
fibers in SIC 2824.
2.3.3 Geographic Distribution Of 1974 Capacities
And Production
Much of the information concerning capacities
and production for the cellulosic and non-cellulosic
fiber industries cannot be presented on a state
basis in order to prevent disclosure of proprietary
information.
11-54
-------
TABLE 11-24
ESTIMATED 1874 GEOGRAPHIC DISTRIBUTION
OF PLANT AGE OF NON-CELLULOSIC
SYNTHETIC FIBERS, SIC 2824
IV
X
IX
VI
IX
VIII
I
III
IV
IV
IX
X
V
V
VII
VII
IV
VI
:
III
I
V
V
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Ker.tuckv
Louisiana
Maine
Maryland
Massachusetts
Ml jr.: -an
Minnesota
Number
Product
Unit
9
2
1
2
6
10
2
1
1
1
3
1
1
nf
Lion 0-4
4
1
1
3
4
2
1
Plant Age
5-9 10-19 20-29 30*
311
1 1
1
1 1 1
5 1
2
1
1
li:i
1 2
1
IV "!==• SSIFC!
VII
VIII
Mi ssouri
Montana
2
2
VII Nebraska
:x
Nevada
: Sew Hampshire
;:
New 'ersev
4
1 3
"I New Mexico
;;
IV
Sew York
North Carolina
7
20
3
9
4
632
VII: North Dakota
Ohio
2
1
1
VI Oklahor.a
f.
Ill
I
IV
Oreoon
Penn sy 1 van i a
Rhode Island
South Carolina
5
1
25
2
9
1 1 1
1
11 3 2
VI'I South Dakota
IV
VI
Tennessee
Texas
17
1
1
1
682
VII! Utah
* Vermont
in
X
in
V
Virginia
Washington-
West Virginia
Wisconsin
19
1
2
1
6
1
1
4711
1 1
VIII Wyoming
Source
TOTAL
Recion I
II
III
IV
V
v:
VII
VIII
IX
X
: "Base Book of
153
6
11
35
87
5
2
4
2
1
Textile
52
1
3
11
3Q
3
1
2
1
Statistics" ,
46 40 11 4
3 2
1234
2 11 8
32 16
1 1
1
2
1 1
Textile Srtjanon, Vol. XXXIII Nc . 1,
New York, Textile Economics Bureau, January, 1962, and Foster 0. Snell,
Inc., analysis of information frcrr subsequent issues of Textile Drganon.
11-55
-------
X
V
V
VII
Vll
IV
VI
I
ni
i
V
V
IV
Vll
v:n
Vll
ix
i
ij
VJ
IJ
rv
VII!
\
VJ
x
in
i
rv
vm
rv
vj
V1I1
i
in
x
in
v
TABLE 11-21
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLANT AGE
SYNTHETIC FIB-*S — Si: 2814
Nylon and Aramid
rv
X
IX
VI
IX
VID
I
III
rv
rv
Alabsrra
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Total Plant Age (Years)
No of 5 or
Plants Less 5-10 10-20 20-30 30 or more
2 1 1
\ 3
2 1 1
1 1
Hawe..
Idaho
Illinois
Iowa
Kansas
Lousf .*r.a
Maine
Mar-.: ant!
Massachusetts
M:ss:ss;pr.
Missojr:
Mor.:ar.a
Ne-.ada
New Hairpsl~.'.re
Jers?\
New Me.vcc
New York
1 1
North 3ako:a
Ohio
r.rf vlvar.ia
Rhode Ular.d
South Carol.r.a
10
2 S
South Dakota
Tennessee
Texas
Virginia
2 1
Wes:
Wisconsin
Vfyaniing
TOTAL
38
£ 11
15
Region
II
UI
K
i
11
25
I
2 1 6
4 10 7 4
2
V
VI
vn
1
1
VIII
rx
X
Source: "Base Book of Textile Statistics". Textile Qrganon. Vol XXXHI No 1.
N«w York. Textile Economics Bureau, January 1962. and Foster D
Snell. Inc analysis of information from subsequent issues of
Textile Organon.
11-56
-------
IV
IX
VI
IX
III
TV
IX
Total
No. of
Plants
TABLE ]] 2:
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLAN'T AGE
SYNTHETIC FIBERS -- P. IC 2624
Other
Non-Cellulosic
Plant Age (Years)
5 or
Less 5-10 10-20 20-30 30 or more
Alabama
Alaska
Arizona
Arkansas
California
VIII Colorado
Connecticut
Delaware
Florida
IV Georgia
Hawaii
IB
Idaho
Illinois
Indiana
VII
VII
Iowa
Kansas
VI
Kentucky
Louisiana
ni
Maine
Maryland
Massachusetts
Michigan
IS
Minnesota
IV Mississippi
VII
Missouri
VIII Montana
VII
IX
VI
IV
II!
IV
IV
VI
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
VIH North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
.'ID South Dakota
Tennessee
Texas
VIII Utah
TOTAL
JH.
IX
IB
1
III
X
T'l
V
Vermont
Virginia 3 IP 2FX
Washington
West Virginia ....
Wisconsin —
W yoming
10
Region
1
11
1
2
1
1 1
VIII
Key:
B - biconstituent
S - Saran
X - Spandex
F - Fluorocarbon
P - Polycarbonate
Source: "Base Book of Textile Statistics". Textile Organon , Vol XXXIII No 1,
New York. Textile Economics Bureau, January 1962. and Foster D
Snell. Inc. analysis of information from subsequent issues of
Textile Organon
-------
rv
x
ix
V]
IX
VIP
1
ni
rv
iv
ix
x
v
V
VII
VII
IV
VI
1
ni
i
V
V
IV
VI!
VII!
Vll
!X
TABLE U-28
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLANT AGE
SYNTHETIC FIBEPS — S!C 2824
Polyester
Total
No of
Plan's
Plant Age (Years)
5 or
Less 5-10 10-20
20-30 30 or more
Alatarra
Alaska
Ar:;or.a
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Hawaii
Illinois
ij
VI
n
rv
v:n
v
vi
x
m
i
iv
vin
rv
vi
vm
i
HI
X
111
V
V1D
Indiana
Iowa
Kansas
Kenvjckv
Leu
Massachusetts
Michigan
Minnesota
Mississippi
Montana
Nebraska
Nevada
New Hampshire
\e-* Vex.
\ev
11
5 3
Ohio
Oreco;.
Per.r.f v^var.a
South Carolina
10
J L
South Dakota
Terressee
Texa'
Utah
Vermont
V;r£:r'.,a
J. 2.
Washington
West V.rg;nia
Wisconsin
Wyoming
TOTAL
39
16 14
Region
11
m
rv
v
i i
B 35
29 13 9 6 1
1 1
VI
vn
vni
rx
y.
Source "Base Book of Textile Statistics". Textile Organon. Vol XXXIII No 1.
New York. Textile Economics Bureau. January 1962. and Foster D
Snell. Inc analysis of information from subsequent issuesof
Textile Organon
11-58
-------
TABLE 11-25
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLANT AGE
SVN'THETIC FIBF^S -- SIC 2824
Potyolefms and Vinyon
rv
X
IX
VI
IX
VIII
1
DI
rv
IV
i.\
X
V
V
VII
VII
rv
V!
i
in
i
V
V
rv
VI!
v;u
VII
IN
1
!i
r.
vi::
V
V!
X
111
1
rv
V:E
IV
V!
VIII
i
n:
X
in
V
VID
A.abat-d
Alaska
Aruor.a
A r k an s a ?
Cai.fc rr.ia
Colorado
Cor.nccucu:
Delav. are
Florida
Gecrg.a
H a w a i :
Idaho
I:l:no:s
Indiana
low a
Kansas
Kerv.ui.kv
Lou:i:A-3
Ms.ne
Mar \ lane!
Mais-ach'jset'.i
V . cr\ . z ar;
M.r.reso-.a
Via? .**•.??•.
M:ssD-::
N'.cr.iar.a
\et- -3Clc =
NevdCo
New Hampfh-.re
S'evi Jersrv
New M e x - c c
Nfw York
N : :v- Ca: ;..:.=
v.;--.r. Tikr-.a
Or-.io
&A.a.vcn?a
Orejc::
Fer.r.? \'l\'ar:. a
R.lrci Is.ar.d
South Carol. ra
Scuth Dakota
T er. ~ e s s e e
Texa^
Utah
Verrr.cr.1.
V ; r f . n 1 5
'A'a=h.r
-------
TABLE II- a:
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF PLANT AGE
c FISr°? — ?IC 2624
Acrylic and Modacryhc
Total
No of
Plants
Plant Age (Years)
5 or
Less
5-10 10-20 20-30 30 or more
IV
X
IX
VI
IX
VID
I
01
IV
iv
ix
X
V
V
VII
VII
rv
vi
i
ni
i
v
v
IV
VII
VIII
VII
ix
i
n
VI
IJ
IV
V1I1
V
VI
X
II!
I
Alabama
1
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michiean
Minnesota
Mississipp;
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jeriev
New Mex.cc
New York
North Car;::r.a
Nor;.1-. Dakota
Ohio
Okiaho-a
Oreeon
Per..-.? v:van:a
Rhode Isiand
South Carolina
VID South Dakota
Tennessee
VI
Vlll
1
HI
X
III
V
vin
Texas
L'tah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region
n
ni 2
IV 4
V
2
2 2
VI
vn
vni
DC
X
Source: "Base Book of Textile Statistics" . Textile Organon. Vol XXXIII No
New York. Textile Economics Bureau, January 19S2. and Foster D
Snell. Inc analysis of information from subsequent issues of
Textile Organon.
11-60
-------
2.3.3.1 Cellulosic Man-Made Fiber Industry,
SIC 2823
Table 11-31 presents the estimated
geographic distribution of cellulosic fiber
capacities for 1974. Table 11-32 does the
same for production.
Total reported capacity was
3,435 KKKg in 1974. Capacity was
split almost equally between the
rayon and acetate classes of fibers.
Total reported cellulosic fiber
production was approximately
537.6 KKKg in 1974. This was
only 15% of the reported capacity.
Most production in this industry centered
in the South Atlantic states.
2.3.3.2 Non-Cellulosic Man-Made Fiber
Industry, SIC 2824
Table 11-33 presents the estimate
geographic distribution of non-cellulosic
man-made fiber capacities for 1974.
Table 11-34 does the same for production.
Total reported capacity for 1974
was 17,592 KKKg. The greatest
capacity exists for polyester
based fibers followed by the nylons.
These two fibers account for
approximately 81% of U.S. capacity
for fiber production.
Total reported production was
137,000 KKKg in 1974. This
represented an over 77% capacity
utilization which was over five
times that for cellulosic fibers.
As in the case of cellulosic fibers,
non-cellulosic production is centered in the
South Atlantic states near the large textile•
mills.
11-61
-------
TABLE 11-31
ESTIV-f.TED 1974
GEOGRAPHIC DISTRIBUTION OF
CELLULOSIC FIBER CAPACITIES
—SIC 2823 (XKKg/vr)
Rayon.
Rayon Staple
Filament And Tow
Acetate.
Acetate Staple
Filament And Tow
IV
X
IX
VI
IX
VIII
I
III
IV
IV
DC
X
V
V
VII
Vll
IV
VI
I
ni
i
V
v
IV
VI!
VII!
VII
IX
I
11
VI
II
rv
VIII
V
VI
X
111
1
rv
V1D
IV
VI
VIII
i
in
X
111
V
vin
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Ilhnoif
Indiana
Iowa
Kansas
Ker:tuckv
Lou:s:sr>a
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersev
New Mexico
New York
North Carolina
Nor:h Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee (D)
Texas
Utah
Vermont
Virginia
Washington
West Virginia (D)
Wisconsin
Wyoming
TOTAL 210
Region I
II
III (D)
IV (D)
(D)ID
(D)
(D)
(D)
(D) (D)
(D) (Dl (D)
(D) (Dl (D)
(D)
1595 850 780
(D) 475 (D)
(D) 375 (D)
V
VI
vn
vni
IX
X
(1)
(D) - data not presented to avoid disclosure
Source: Snell analysis of information supplied by the Textile Economics Bureau
and from Textile Organon . Vol XLVI. No. 8. New York. Textile Economics
Bureau. September 1975.
11-62
-------
TABLE H-32
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF
CELLULOSIC FIBER PRODUCT!n-
--SIC 2823 (KKKg/yr)
Rayon
Filament
Rayon
Staple 6 Tow
(Dirn—
Acetate Acetate
Filament Staple 6 Tow
rv
X
IX
VI
IX
VIP
I
Alabama
Alaska
Arizona
Arkansas
Cai::'crn:a
Colorado
Connecticut
Delaware
Florida
[V
IV
IX
X
V
V
Vll
Vll
IV
VI
1
ni
i
v
v
rv
vn
vi::
vii
ix
i
ij
Vj
n
r\__
VII!
v
vi
X
George
(D)
Hawai
Idaho
Hiinois
Indiana
ICW 3
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
(D)
M.chi gar.
Minnesota
Mississippi
Missouri
Vc-r.ta.-.a
Nebraska
Nevada
New Harrpsh:
New Jersey_
New .Ve.\:cc'
New Vrrk
Nc-r-.h Career
Ohio
reec:.
(Dl
I
rv
vin
rv
VI
VIII
i
in
Rhode Island
South Carolina
South Dakota
Tennessee (D) (Di
Texas
Utah
Vermont
Viremia ID)
(D)
(Dj
(Dr
X Wa-hir.jrton
III
V
Wes: Vire-.nia (D) (Dl
Wisconsin
Vin Wyoming
TOTAL
78 3
294 3
165
none rercrte-
Region
III
(D)
(Dl
IV
(Dl
(Di
73
VI
VD
DC
111 (D) - data not presented to avoid disclosure
Source Snell anaJysis of information from Textile Organ or.. Volume XLVI. No 1-2,
New York, Textile Economics Bureau. January-February. 1975
11-63
-------
TABLC 11-33
ESTIMATED 1974
GEOGRAPHIC DISTRIBUTION OF
NON-CELLULOSIC FIBER
CAPACITIES — SIC 2824 IKKKo'
rv
X
IX
VI
IX
vi n
i
21
rv
IV
LX
X
V
V
VII
VII
rv
VI
I
III
I
V
V
IV
ll II III
z u. Z < Z v.
Alabama (D)<2> (D) (D)
Alaska
Ariror.a
Arkansas
California
Colorado
Connpcticui
De. aware (Di (D)
Florida (D) (D) (D)
Georgia (Di
Hawaii
Idaho
Illinois
Ind.a-a
low a (D)
Kansas
Kentuckv
Louisiana
Maine
Maryla-.d (Dj
Massachusetts
M-chitar
Minnesota
N'15?.>51?31
- c ~ ~ zf
K e: KB- — c
H it H
1C) 13) (D) NA
(D)
(D)
ID'
(D)
NA
(D)
ID)
(D)
(D ( NA
tD'
ID)
.D:
u i
~c - C
(D)
(D/
(D- (Di
(Di
\'ll Missouri (Di
VIII
VI!
IX
I
1)
VI
;;
rv
Mortar.a
Nebraska
Nevada
New Hsrrrihire
\ew .'e.--?v
New V«xt"
Ne» Vcrk 'D
North Car:. .r.a 265 {D
ID-
•D ID:
13t: iD.' NA
!D
;£
(D'
VIII Ncr-.r D = r.:ti
V
VI
\
III
I
IV
vin
IV
VI
VIII
i
ir>
X
in
V
VIE
OhJC
Oklahcrr.i
Oregon
Penr.svlvar.ia (Di
Rhode island
South Carolina 1190 5"0 (DI
South Dakota
Tennessee 615 375 (D)
Texas
Utah
Vermont
Virginia 945 (D) (D)
Wash.r. z:or.
West Virginia (Di (D)
Wisconsin
Wyoir.ing
TOTAL 4215 1'30 1770
Region I
II (D)
11! 1475 575 (D>
R- 2730 1155 (D)
V
VI
VD (D)
ID iD>
iD i (D
(DJ
i:30 (D; iD)
99C'-3' (D) NA
(D)
(D! (Di (Di
(D)
ID)
(D!
4080 4290 1120
250
(D) 130
375 (D) 190
3585 ID) 490
(D) (D)
ID)
(D)
(Dj
ID) ID-
iD)
iC) (Di
355 35l-
ID) ID)
iDi
(DI (D!
(D) (D)
VIII
DC
(D)
X
Notes:
(1) Primarily saran and spandex
(2) (D) - data not presented to avoid disclosure
(3) (C) = polyester filament capacities for AL arid TN combined to avoid disclosure
Source: Snell analysis of information supplied by the Textile Economics Bureau
and frotr Textile Organon . Vol. XLVI, No 9. New York. Textile Economics
Bureau. September 1975
11-64
-------
TABLE H- 34
ESTI.-J.TEr 19~4
GEOGRAPHIC DlSThJb 'JT1V.
OF NOK-CELLULOSJC FIBER
PRODUCT:ON -- s:r :?:4 »j
rv
X
IX
VI
IX
V113
I
DI
IV
IV
IX
X
V
V
VI]
VII
I\
VI
1
11!
)
V
V
IV
VI)
VIII
VI]
IX
I
i;
V!
]*
IV
VII!
V
V!
X
11]
1
rv
vin
rv
VI
VIII
i
in
\
in
V
vin
C."
- |g
Alabama (Dl^'( (b \
AlB^kb
AT,: or b
Arkansas
California
Colorado
Connecticut
Delaware [DI ID)
Flor.idb ID) mi
Ceorf.it (D i
Ha*;::
Idahc
!!!:no:s
Indiana
Iowa (D i
Kansas
Ker.'. _.KV
Lou:s.hr.i
Maine
Mar;, .and (Di
M.chiiar,
Minnesota
Miss:ss:pp:
M:sso-jr:
Montana
N'etraiks
\evaci
New Harr.p?r::re
New Jerse\
New Mex-cc
New Yor)< (D
NTth Ca'c::r.i 215 (Dj
Ncr'.r. Dekcti
Oh it
Ok.'ihrrta
Orecc:-.
Per.nsvlvsn.a (D,
Rnode IsianS
South Carolina 970 410
South Dakota
Tennessee 500 275
Texa<
ft ah
Vermor.t
Virg:r.;s 770 (D)
Wa^hTglO"
Kest V.yg:n-.a (D i (D '
Wisconsin
Wyonine
TOTAL 3430 1245
Region 1
11 (D I
III 1190 415
R' 2225 830
V
V]
vn ID)
vni
D;
X
. 1 1 1
H| t- tl =? si -
111 |l ft |! |I 1
(D)
(D)
(D)
(1) Primarily saran and spandex
(2) (D) - d»ta not presented to avoid disclosure
(3) Polyester filament production for AL and TM combined to avoid disclosure
Source: Snell analysis of data presented in Textile Organon. Vol XLVI No 1-
New York. Textile Economics Bureau. January-February 1975.
11-65
-------
3. PROCESS DESCRIPTIONS AND WASTE STREAM IDENTIFICATION FOR
THE PLASTIC MATERIALS AND SYNTHETICS INDUSTRY, SIC 282
There are two major groups of processes used in SIC
282: polymerization and spinning. Because polymerization
processes are similar for all segments of this industry, the
SIC Classification framework for the discussion presented
below is not maintained. Instead, these topics are presented
in a manner more descriptive of the actual conditions in the
industry.
The section is organized as follows:
General description of the polymerization
process to provide a technical framework for
the understanding of the individual processes.
General description and quantification of
waste stream factors.
Specific, more detailed description of the
processes and waste streams. This descrip-
tion is subdivided into several parts so that
the various aspects of SIC 282 are covered in
a logical format. In particular, regarding
plastic resins and synthetic rubber, the
discussion addresses itself to:
Processes and waste streams associated
with olefinic polymers
Processes and waste streams associated
with the non-olefinic polymers used in
man-made non-cellulosic fiber manu-
facture
Process and waste streams associated
with the principal other non-olefinic
polymers
Processes and waste streams associated
with the production of man-made cellu-
losic polymers
- Processes and waste stream associated
with the spinning operations.
11-66
-------
Note that for the purposes of this study the term
olefinic polymer refers to those polymers where the main
linkage generally occurs at a carbon-carbon double bond
site.
3.1 Introduction
This section provides a general description of the
polymerization process and of the waste streams gener-
ated.
The rationale for this approach is that there
exist fundamental similarities among most of the
polymerization processes. However, this section does
not discuss the processes involved in the production of
cellulosic man-made polymers nor the various spinning
processes which are discussed separately in the last
paragraphs of the following section. This is because:
Cellulosic man-made polymers are prepared by
different methods from the production of the
other synthetic polymers (albeit often at
the same production sites).
Spinning operations are a different technology
from polymerization.
3.1.1 General Description of the Polymerization
Process
In general, polymerization is the linking
together of single molecules (monomer) to form
repeating units of one or several molecular species,
Two problems of the polymerization process are:
The efficient removal of the considerable .
amount of heat generated in the process of
polymerization.
The change of phase to an extremely viscous
or even solid material of a liquid or gaseous
monomer.
These two problems are usually solved simul- .
taneously by providing a carrier fluid for the
final product. In most instances, this carrier
fluid is water; in which case the processes are
described as emulsion or suspension polymeriza-
tion. When the carrier fluid is not water, it can
be an organic solvent. In this case, the process
is known as solution polymerization. Another
approach is that of using an excess monomer acting
as a solvent. These processes are known as bulk
polymerization.
11-67
-------
The above processes can be run batchwise, semi-
continuously or continuously.
Pressures involved in the reactions may vary
from near atmospheric to thousands of atmospheres
(40,000 p.s.i.). Temperatures may range from near
room temperature, 20°C (70°F) to 175°C (300°F).
Catalysts or initiators may be involved. However,
in most cases they are consumed in the process or
are incorporated in the final product. Spent cata-
lysts may sometimes become part of the waste stream.
The following steps that are common to most
processes have been previously listed on p. II-8 and
include:
Monomer(s) storage
Monomer(s) feeding to the reactor
Carrier feeding to the reactor (except for
bulk processes)
Catalyst feeding to the reactor
Reaction
Monomer(s) recovery
When required, carrier recovery
Processing of the polymer.
These steps and their interactions are presented
in Figure II-l.
In some instances it is necessary to condition
the monomer by removing the inhibitor.
Most facilities produce hundreds of millions of
pounds per year. However, about 10% of the total pro-
duction is carried out in extremely small scale op-
erations, i.e., several thousand pounds per year.
Tables 11-35 and 11-36 summarize the production
elements for the major plastics and synthetic rubbers,
respectively.
3.1.2 General Description Of The Waste Streams From
Polymerization
The waste streams produced in polymerization are
described next. There are six major classes of waste
streams.
11-68
-------
Table 11-35
SUMMARY or rHODUCTIOK tLEkCKTS IN THE
PLASTIC «£SINS DJDUSTHV —
ProiiiCt
Polyethylene
lov D«r«iry
High Denelry
Poly-vinyl Chloride
Poryvryicne
AB5-SAS
Polypropvtene
Phenolici
(5)
PoKesten
Alkydi
Acrylics
Polyamidei
\.lon l.t
v- Ion £
tocceat Carrier Fluid
Modified bilk
Solvent CoJvejn (60- VfC I. P . )
Sn^envjoc/Emulsion Water
Sulk Hone
Suspecslon water
Htlk /Solution Mry Ibentt ne
EmuLdon Water
Soluoon Heptane, cyclohexane
vylene
QnulsioE water14'
Mass None
Fun or :-,,,,; None
Solvent ' so: jt ion) Xytene, mineral apmu
EmulKion/Sucpcn&or. Water
Solvent Vartoui aolveou
Bulk Mooomet
Suspension water
Suspension water
MoDomer(t^
Ctbytene
ttbylene'2'
VCM
VCM
Ctyrcne
Sryieoe
Aery lonl Mle.
butadiene, ffyrene
Propylene
Formaldehyde (31%
phenol and lubrdtuied
p he nob
Polyalcoholi. dlbailc
•eld or anhydride
Ptathalic anhydride
Fairy acidi, cili. glycoh.
polybaelc acidi
Acrylates
Acrylates
ktethyl metbacrylate
Hexameth) leoe dlamlne
Caprolactam
taia«tof
ot Catiliit'1'
Ckvanlc aeroxldei
Ztegler/PblUlpt'31
Lumyl peroxide
•aobiMoturyronltrik
(aame)
Laaroyl paratide
aioblilicburyronltrlu
•emoyl peroxloe
fenyl pelfaemoate
Peronoei
Zlegler (Al, Tl)
AUtaltei 01 Acldi
Aoetaiei of cobalt,
manganeee or cadmluiD
None
EmuUifien. penulfatei
Peroindei
None
Kylon 6,6 or u arnlno
caproic acid
Additlvei
Polyrlnyl alcohol, gelaon.
nethylccltuloie
»»«pel«tary (If an) )
Telcalciiun pboaphate,
•vfactanti, dyei
Catfoon cenachlohdj
•hortEtcj Thycro-
quinine) pigments.
plaaticizere
Anaoxldana. fillen.
pUatlciun. antuuB
Solwnu. eib. plartcUen.
wood flour, other nuni.
c. |. amlDo Kdra
Stytcae, bydroqoinone
Deducing agenu, feme
ammonium lulfate
Aceuc acid. TiO .
spin ftniihet 2
Acetic acic. TiOj.
ipin ftnuhes
ABS-5«\ : Acr\lonlmle butadiene fryrene-Sryrene acrylooltrile
(1) Tne (ermi catalyn and initiator are uaed lome^hat interchangeab!), in po!ymeii2auo£. Jniriaiors are. by oeliniDon, uieo
up ir the reaction and theU decompojltfoii pioducn an nftiaUy diichats«d wlt> the polymer. Catalj-iu ar« leldom aeparited
at coe end of the reaction.
(2i Copclv meniauor. it frequent (a current comonomet may be vinyl acetate).
i3; Zieglet catalytu " liopropyl 01 iiobun-1 hydridei — Phillipi A ceramic type chromium oxide , aluminum oxide finely divided icuc.
(4) The water i- luppUed frorr. the lac of i want iclution of formaldehyde (FormaUn 3T%
(5] The bulk of the production u lor fibet and ii o/ten carried out In fiber plann (SIC SS24).
Source Forter D. Snell. Inc. analyni of Industry interviewi and lit*rarur« information.
11-69
-------
Table 11-36
IUMMAIY Or nODl'CTKV. tU>!TVrS p. T»«
STNT»KTIC KtmiL INDI-STI-V —
MCttH
Prodjci
55S U»»
S6i> Cnin-.t
SfS Maaierbaict.
?ft Oil Extended
SrF. Cr-— '
Pol-tniiadiene
-ol uoprene
Eur! and CUoiobar. 1
Riiboej
\coprene
W. «r.c! Err"
>ojrcei t'R1 M. Morton.
rracen C*mc> fluid Monomentl
Emuluon Want Sijnuc. kitMMM
Emulson waier Sly«BM. femdfetat
Emulsion Water Slytcne. kiudune
Solution Hydrocarbon Solvent Stviene. lutaacne
Solution H\-dioc«jbon Solvent Siyiene. Ibfadieiie
Solution HydtocaibOD Solvent Ittuoteae
Solution htj-diocarten Solvent bopieoe
Solution x*th>l Chlortd« Heune bobutylene /bofuene
EmuUion Water ChtoiopKDe
Solution Hydracaiten Solvent Ethytar»-Prop) knt
Elb)U»«nt. Notbcmnt
Mibbet Technologv . Second Edition. Van Noraand (1973). t.cepi wkeie aomd.
Catalvr-
rwcnoet
-—
Aodic.ct
laa;. Fe or t ula.
Saa*. Fe or K iala.
-- - • -
njvnHravuw*
r?ma4ct C*rtwr. OUck. Soap.
Enendci Oil. Dodcc I-
MwcMiatc F* or K SA)U
Mvdioqulnone
Uttactr. AUn tfi
Utblum Att>d»
TiutuuiD. Vanadiurr.
Zlicoittiim Nalnlei,
(K) Aluminum Aito 01
Aluminuir. Tiialkj 1
Titanium Tena-
cUoclaB
Aluminum CblMMe
Potatuun: Pen»c>dt-
•uUatt (K). Sulfui
Vanadiurr Orcnlor-
Ide. Aluminum
Alkylchlonoci
Eneooti Cfh
rnpneur. letnen-)
Piopnetan tetheR^>
Pnpneun
Plopneur. lean be o:
J
CAiciuir jn§nif , Antj'
•attdant. Cblannt Cat
(far cUorobun I)
Saptntuknt Sullo.uc
Acid. FotmaMthde.
Soap. Teuacth> Itaituar
Subitu<> auC anuou
(^loertttan 1
'*•*" '
) KiFfc Oihmct. Cncyclooedii of Cbemlc*! Technology . Second tdinoo. IBUIKKHU (19(4)
11-70
-------
3.1.2.1 Off-Grade Products
The main waste stream, in these processes, con-
sists of off-grade products. The reasons are production
upsets, product changes, mechanical failures and abra-
sion in handling.
3.1.2.2 Still Bottoms
This stream originates in monomer or solvent
recovery. It is composed of high boiling residues
called still bottoms, which are separated in the dis-
tillation process. These residues consist of relatively
low molecular weight, shortchain polymerized material
and other organic products resulting from chemical
degradation of product or solvent.
3.1.2.3 Spent Adsorbents And Filters
Granular or pulverulent material (adsorbent)
is used to condition the monomer by removing traces
of water. This material is eventually discarded, and,
together with the filter elements used from its separation
from the production stream, constitutes a significant
solid waste stream.
3.1.2.4 Spent Catalysts
In some processes, spent catalyst constitutes
a separate waste stream. In this industry, in many
cases, the catalyst is allowed to remain in the finished
product and thus does not constitute a waste stream.
In other cases, the catalyst goes to the wastewater
treatment facility and becomes part of the sludge.
3.1.2.5 Waste Oils
There are two sources of waste oils:
Spillage from gear boxes and bearings of
rotating equipment
Oil changes.
The spillage usually finds its way to run-off
sewers or floor drains. If spillage at a plant is
significant, traps are provided to collect the waste
oil. Spent lubricating oils are generally collected
in drums.
11-71
-------
3.1.2.6 Wastewater Treatment Sludges
The plants in which most of the polymerization
processes are carried out have usually some form of
treatment facilities for their wastewaters. The con-
tribution of the polymerization processes does not
constitue/ in the majority of cases, the bulk or
even a major portion of the wastewater loads. This is
due to the fact that at most plant locations other
processes are carried out which require large quantities
of process water, and which are more likely to contami-
nate the water with undesirable components.
The treatment of wastewater generated in chemical
plants usually involve at least a clarification step.
Clarification may be preceeded by such steps as
pH adjustment and/or the addition of flocculant or
coagulant. Clarification produces a sludge which may
contain solids from the polymerization process. In
addition to the catalysts discussed in the previous
paragraph, the primary sludges may also contain fines
from the polymerization processes.
In addition, there may be a secondary treatment
operation in which soluble contaminants (e.g., alcohols)
from the polymerization are oxidized biologically and
produce a biological sludge.
Because SIC 282 plants are usually part of large
chemical complexes, the contribution of the polymerization
processes to the total wastewater load is minor.
3.2 Detailed Process Descriptions
In this section, the various processes used to
manufacture the subject polymers are discussed in more
detail. Although many classifications and segmentations
are valid, the general framework for the discussion
is based on a segregation of the processes into five
groups. The first four groups cover the processes used
in the manufacture of the polymers, while the last group
addresses itself to the spinning.
11-72
-------
In view of processing commonalities, the first
group of processes discussed contains those used for
what we call the olefinic polymers. This group en-
compasses most of the major polymers derived from
olefinic materials, with the addition of vinyl chloride
and acrylonitrile. The group encompasses all the major
synthetic elastomers and the other major resins (i.e.,
polypropylene, polyethylene, styrene butadiene rubber).
A second group consists of the three classes of
polymers used in the non-cellulosic fiber industry.
These are less directly related to the petrochemical
industry because the monomers involved are produced
in chemical plants (i.e., acrylics, polyesters).
A third group consists of other non-olefinic
resins, usually manufactured by batch processes. In
terms of volume of production, this group is dominated
by the phenolics and amino resins (i.e., phenolics,
epoxies, alkyd resins).
The fourth group comprises the cellulosic man-made
(or man-modified) polymers (i.e., rayons and acetates).
3.2.1 Processes And Waste Streams Associated With
The Production Of Olefinic Polymers
The types of polymers included in this group are
as follows:
Styrene Butadiene Rubber (SBR)
Polyethylene: low and high density
Polyvinyl Chloride and Polyvinyl Acetate
Polystyrene and other styrene resins (ABS*
and SAN**)
Polybutadiene
Polypropylene
Neoprene
EPM-EPDM Rubbers
Polybutenes and Copolymers.
Table 11-37 illustrates the waste factors associated
with the above olefinic polymers.
The processes used include:
Emulsion and suspension polymerization
Mass or bulk polymerization
Solution polymerization.
ABS= Acrylonitrile butadiene styrene
SAN= Styrene acrylontrile
11-73
-------
TABLE 11-37
ESTIMATED WASTE FACTORS ASSOCIATED WITH
THE PRODUCTION OF OLEFINIC POLYMERS AS A
PERCENT OF TOTAL PRODUCTION—
SIC 282
I
-J
Product
Styrene Butadiene
Rubber (SBR)
Polyethylene
Low Density
High Density
Vinyl Resins
Chloride
Acetate
Styrene Resins
Polystyrene
ABS-SAN
Polybutadiene
Polypropylene
Neoprene
EPM-EPDM Rubbers
ABS * Acrylonitrile
N.A. - Not Applicable
Production
(KKKg/Yr. )
2,216
4,018
-
-
2,277
-
-
2,244
-
477
2,196
177
163
butadiene styrene
Estimated Waste Factors (% of Total Production)
Off-Grade Products Still Bottoms
and Waste Oils
2.5
-
1.0
0.3
_
2.0
1.0
-
0.2
2.0
0.2
0.5
3.0
None Reported
SAN<*
1.15
-
1.00
0.05
-
N.A.
0.1
-
1.0
0.5
0.01
1.0
6.0
None Reported
Styrene acrylontrile
Other
Wastewater Sludge
-
N.A.
Spent Adsorbent
and Catalyst
-
Wastewater Sludge
N.A.
-
N.A.
Wastewater Sludge
Spent Adsorbent
Wastewater Sludge
(Dry)
Nitrile waste
N.A.
Spent Adsorbent
and Catalyst
1.3
Less than
0.1
1.1
1.0
0.01
0.20
0.05
Less than
0.1
Source: Foster D. Snell, Inc.
-------
A series of figures are provided to illustrate
the processes and waste streams discussed under olefinic
polymer.
Figure II-2 — Emulsion/Suspension Polymerization
Figure II-3 — Bulk or Mass Polymerization
Figure II-4 — Solution Polymerization, Phillips
Process
Figure II-5 — Solution Polymerization, Ziegler
Process
Figure II-6 — Particle Form Polymerization
11-75
-------
3.2.1.1 Emulsion And Suspension Polymerization
Figure II-2 presents a flow diagram of a typical
emulsion/suspension polymerization process. The
wastes include:
Off-grade products—fines and scrap pellets
Still bottoms—polymer waste
Wastewater sludges.
A large number of polymers are manufactured by
processes in which the monomer is dispersed in an
aqueous, continuous phase during the course of the
reaction. There are technical differences between
emulsion and suspension systems which pertain to the
polymerization reaction itself, but do not have a
bearing on the waste production. Therefore, both
methods are covered by this discussion.
Batch processes are commonly used. Typical
reactor size is 18.9 to 113.5 m (5,000 to 30,000
gal.). The batch cycle consists of the continuous
introduction of a water-monomer emulsion with agita-
tion. Polymerization occurs at about the rate of
monomer addition; the heat of reaction is removed
by cooling tower water circulated through the jacket.
The reactor is vented through a condenser for monomer
recovery; and the condensate, including any water, is
returned directly to the vessel. On completion of
the batch, a short "soaking" time is allowed for com-
pletion of the reaction, and water is then added'to
dilute to the desired end composition. The batch is
drawn off through a screen to product storage. Over-
size screenings constitute a waste stream.
A number of products, polyvinyl acetate for
example, are marketed in latex form with no further
processing required. When the product is isolated and
sold in solid form, the screen latex is pumped to another
tank where it is coagulated. The liquid phase is
separated by centrifugation or filtration and the
cake is dried.
11-76
-------
H
M
I
r
£
H
is-
in
Source: Environmental Protection Agency Study (Con
fl 1
o Acrylonjtrile__^pl
z
o
Oi
oo
1
o
o
o
CJ
p
Polymer
Waste** "
Butadiene ^
Poly me
t
Poly me
J '
Extrusion
., 1 1 — Scrap
Pellets
1
Coagulation
A ' '
T Watet J
Steam Fines -* — * <
in water
Polymerization to sludge Extrusion
I'elletizing
1
Scrap ^ _|
Pellets
\vaste Water ^ <;,,„,,,„,
Treatment
SAN Resin
Fines from dust
collectors
ABS
Resin
FIGURE II-2
EMULSIW/SUSPENSION POLYMERIZATION FUDW DIAGRAM
-------
The emulsion process is probably the most
important in polymer manufacture. It is used in
particular in the production of the following
olefinic polymers:
Styrene-butadiene rubber (SBR)*
Polystyrene
Acrylonitrile butadiene styrene (ABS)
Styrene acrylonitrile (SAN)
Polyvinyl chloride (PVC)*
Polyvinyl acetate (PVAC)
Neoprene.
3.2.1.2 Mass Or Bulk Polymerization
In these processes/ an excess of the monomer
is used as the diluent or carrier fluid. There are
two types of processes:
Low pressure polymerization
High pressure polymerization.
Figure II-3 presents a typical bulk or mass poly-
merization flow diagram.
3.2.1.2.1 Atmospheric Or Low Pressure Mass
Polymer i zation
A number of important polymers are manufactured
by mass polymerization, a system in which the puri-
fied monomer is allowed to polymerize under controlled
conditions of temperature and reaction rate. Catalysts
and modifiers are used to initiate the reaction, control
its rate, and influence the final molecular weight.
These materials are used in very small quantities, and
their residue remains in the product. Removal of the
heat of reaction is a difficult problem in this pro-
cess and limits the type of equipment which can be
used.
A substantial production of these polymers is carried
out also by other processes, e.g., solution or mass
(or bulk) polymerization.
11-78
-------
F5
re
3
n
3
•a
3
re
o
o'
3
3
O
o
B>
o.
o
3
ner
i
Mon
Prep
tio
1
jmer
ara-
i
1 !
Inhibitor *
Vacuum
Stripping
Til 1
Heating Cooling
' 9*
f^on- Con-
denser denser _
.
Recti- g »
" fier " §
- '
Oligomer 1
Waste Aqueous Wast
r
•Lxtrusion "iV^ ^/\ *]Pelletizinj^
Vacuum System
Light Ends
Polymer
Waste
Polvmer
Product
I
t
Polymer
Spillage
Waste
Water
Scrap Pellets
Waste Water
Treatment
Sludge
FIGURE II-3
EPA
BULK OR MASS POLYMERIZATION FLOW DIAGRAM
-------
It is usually necessary to protect the purified
monomers from autopolymerization in storage. The
inhibitor used for this purpose is removed by monomer
preparation. The reaction system is usually continuous,
or multi-stage, and the first step is to bring the
monomer to reaction temperature by indirect heating.
A heat-transfer oil or fluid, such as Dowtherm, cir-
culated from a fired heater, is used. Once reaction
begins, the heat is removed by transfer to cooling
oil circulated through coils or in a jacket. The
circulated oil is cooled by water in conventional
heat-exchange equipment.
On leaving the reactor, the polymer contains
unreacted monomer and small amounts of contaminants
and by-products. These materials are removed by
vacuum stripping. The recovered monomer is then
treated in a rectifier. The contaminants and by-
products constitute the oligomer by-product waste
(still bottoms). Pure polymer is forced through ex-
trusion to make strands of polymer, which are cooled
in a water bath before pelletizing for storage and
shipment.
Other wastes include off-grade product, polymer
waste and scrap pellets.
Products of this process include:
Polystyrene (PS)
Acrylonitrile, butadiene, styrene (ABS)
Styrene, acrylonitrile (SAN)
Polyvinyl chloride (PVC).
3.2.1.2.2 High Pressure Mass Polymerization
This process is mainly used for the manufacture
of low density polyethylene.
Ethylene gas is mixed with a very small quantity
of air or oxygenated organic compounds as a catalyst
and with recycled ethylene, and raised to high pressure
in reciprocating compressors.
11-80
-------
The operating pressure is considered to be
confidential information, but the trend in the
industry has been to the highest practical pres-
sures, and literature references to design ratings
of 40,000 psi (2,722 atm) and up are common. At
the operating pressure and at an appropriate
temperature, polymerization is carried out in
jacketed tubular reactors. The heat of reaction
is removed to hot water in the jacket, which cir-
culates through a waste heat boiler for the
generation of steam.
On completion of the reaction, the pressure
is reduced and polymer meeting the specified
properties is separated in flash drums. This
molten material is pumped through a multiple
orifice extruder to an underwater chiller and
chopper to produce polyethylene pellets. A
purge stream of this water is removed and replaced
with high-quality, clean water. The purge is at
a rate sufficient to remove polymer fines generated
in chipping. The quantity of fines depends on the
grade of polymer produced and with some grades is
negligible. Wet polymer from the screen is dried
and stored in silos.
The waste factors in the production of low
density polyethylene consist mainly of off-grade
products (1% of total production) and still bottoms
and waste oils (1% of total production).
3.2.1.3 Solution Polymerization
There are two main variants of this process,
basically depending on the type of catalyst used. The
Phillips processes use a chromium oxide or alumina
type of catalyst and the Ziegler processes use metal
alkyd catalyst. A recent variant of these processes
is called the particle form process.
3.2.1.3.1 Solution Polymerization (Phillips Processes)
In this process (Figure II-4), the polymer is
dissolved in the reaction solvent as it is formed, and
the catalyst is present as a separate solid phase.
The catalyst system is activated chromium oxide de-
posited on a carrier, such as alumina.
11-81
-------
FIGURE II-1*
SOLUTION POLYMERIZATION
(PHILLIPS PROCESS)
Olefin
Solvent
Catalvst
[ ] Cooling
Catalyst
Filtration
Aqueous
Waste
Solvent and
Water Vapor
Fines from
dust collection
Water Stream
Wastewater
Treatment
Sludges containing
waste catalyst 0.1
Kg/1000 Kg product.
Source: EPA publication EPA-440/I-74-010-a
11-82
-------
As the concentration of polymer, or the mole-
cular weight of the polymer in solution increases,
the viscosity of the solution also increases markedly.
This phenomenon places severe limitations on the
processability of the reaction mass. Temperature
control is accomplished by indirect cooling with
refrigerated water, and the viscosity must not be
allowed to exceed a reasonable limit for efficient
heat transfer.
Viscosity is also an important limitation in the
next step, which is the removal of the catalyst by
filtration. From the filter, the catalyst, wet with
solvent, is mixed with hot water and the solvent re-
moved by steam stripping. Solvent-free catalyst slurry
is processed in a skimmer and solid catalyst is pro-
duced as a waste.
The water is recycled to the steam solvent
stripper. Vapor from the steam stripper is combined
with other recovered solvent for purification by
solvent distillation.
The catalyst-free polymer solution is processed
in a system which precipitates the polymer, and then
removes the last traces of solvent by steam stripping,
leaving the polymer as a slurry in water. The poly-
mer water slurry goes to polymerization, and the
filtrate is recycled to the stripper.
Recovered solvent and vapors from the steam
strippers are processed by the solvent distillation
system.
Dry polymer crumb or flake is blended, melted,
extruded and pelletized. This pelletizing operation
is carried out under water, with cooling and transport
accomplished with recirculated, clean, softened water.
A purge stream amounting to a few percent of the cir-
culation rate is withdrawn to waste. This system is
the same as that already described for the low density
polyethylene process.
The principal product of this process is high
density polyethylene. However, the process is also
used for some copolymers in this family of products.
-------
3.2.1.3.2 Solution Polymerization (Ziegler
Processes)
This process (Figure II-5) depends on a catalyst
system discovered and patented by Dr. Karl Ziegler.
There have been a number of improvements by companies
using the basic principle, and the name in fact ap-
plies to the catalyst system. Each user has had to
design his own plant. However, it is convenient to
group under this name all polyolefin processes which
employ a reaction solvent in which the polymer pre-
cipitates as it is formed. The catalyst is a rel-
atively complex alkyl, or alkyl halide, of metals
such as titanium and aluminum.
Catalyst preparation, monomer addition, and
reaction proceed as for the solution process described
in 3.2.1.3.1. Temperatures and pressures are lower;
and, because the polymer does not dissolve, problems
caused by excessive viscosity do not arise.
The next step is the removal of the catalyst,
which historically has been the most troublesome
part of the system. The residual catalyst content
of the final polymer must be very low, and for this
reason a system is employed which allows transfer
of catalyst to a separate liquid phase. Aqueous al-
cohol is used for this purpose and the catalyst is
removed in solution, leaving the polymer slurried in
the hydrocarbon solvent.
The aqueous alcohol phase is treated to precipi-
tate the catalyst as the oxides (e.g., titanium, alumi-
num) , and these materials eventually appear as finely-
divided suspended solids in the aqueous waste. They
will settle sufficiently to permit discharge of a
clarified effluent. Together with very fine product
waste, these oxides constitute the bulk of the sludge
from the waste treatment plant. This amount to 0.1 Kg
per 1000 Kg of product.
Alcohol is recovered for reuse by distillation.
The aqueous phase remaining is the principal waste '
product of the plant.
11-84
-------
FIGURE II-5
SOLUTION POLYMERIZATION
(ZIEGLER PROCESS)
Olefin
Solvent
Catalyst
Cata-
lyst
Prep.
Recycle
Solvent
Product
Steam
Fines in
water stream
Wastewater
Treatment
Fines from
dust collector
p- Sludges
Source: EPA publication EPA-440/l-74-010-a
11-85
-------
The polymer slurry is processed by steam
stripping, filtration, drying, extruding and pellet-
izing as is done for the solution process, and the
hydrocarbon solvent is purified by distillation.
A small quantity of aqueous waste is recycled to
the alcohol unit.
Products obtained by this process include:
High Density Polyethylene
Styrene Butadiene Rubber (SBR)
Polybutadiene
EPM-EPDM Rubber
Butyl and Chlorobutyl Rubber
Polypropylene
Polybutene
Copolymers of this family of monomers.
3.2.1.3.3 Particle Form Process
The problems of the solution process for poly-
olefins have to a large degree been overcome in a
newer version called the particle form process, and
the method has a growing commercial acceptance for the
manufacture of high density polyethylene, polypropylene
and copolymers (Figure II-6). There have been three
major changes:
The catalyst (ethylene and comonomer) system
has been modified so that it can be incorporated
into the polymer. Its activity has been increased
to the point that special measures for catalyst
removal are unnecessary for many grades of polymer.
The hydrocarbon solvent system has been modified
so that the polymer is not as soluble and is
obtained as a slurry rather than a solution in
the diluent.
Special design loop-reactors have been developed
which allow the polymerization system to operate
under good control of reaction conditions and
at satisfactory rate.
11-86
-------
Source EPA publication EPA-440/l-74-010-a
FIGURE II-6
PARTICLE FORM POLYMERIZATION
FLOW DIAGRAM
Olefin Recvcle
Olefin
Feed
Catalvst
Catalyst
Preparation
Loop
Reactor
Wa stewater
Treatment
Con-
denser
Water
.Aqueous Waste
Slurry
Sludges
Fines From
Dust Collector
Polymer
Product
11-87
-------
In this method, catalyst and olefin feed
are added to the reaction mass which is circu-
lated continuously through the loop reactors.
A stream is also withdrawn continuously from the
reactor to a flash drum. Polymer is removed from
the bottom of the flash drum, dried, and processed
through an extruder pelletizer as with the other
methods.
The vapor stream from the flash drum is scrubbed
to remove polymer fines. This step produces a small
quantity of wastewater. Both unreacted olefin and
recovered diluent are then separated from the overhead
stream and recycled to the reaction step.
The products and waste streams of these processes
are essentially the same as reported previously
(3.2.1.3.1 and 3.2.1.3.2).
3.2.2 Non-Olefinic Polymers Used In Fiber
Manufacture
There are three main groups of polymers that are
used in non-cellulosic fiber manufacture: acrylics
and modacrylics, polyamides (nylons) and polyesters.
Olefinic polymers are also used in the manufacture of
fibers (in particular polypropylene) but the production
of these has already been described. The spinning
methods are described in Section 3.2.5.
A series of figures are provided to illustrate
the processes and waste streams discussed under non-
olefinic polymers used in fiber manufacture.
Figure I1-7 — Acrylic and Modacrylic
Figure II-8 — Nylon "6" (Polyamide)
Figure II-9 — Nylon "6,6"° (Polyamide)
Figure 11-10 — Polyester Resin
11-88
-------
3.2.2.1 Acrylics and Modacrylics
The bulk of this production is carried out by
a suspension or emulsion process (Figure II-7).
The monomer acrylonitrile, together with comonomers
such as vinyl chloride(D are added to a reactor
kettle at a ratio of about 10 parts of water to one
part of monomer. The reaction is initiated by
redox catalysts and initiators such as ammonium
perdisulfate, sodium metabisulfite and sulfuric
acid. The common practice is to meter the reactants
and water continuously into the reactor and to ob-
tain the polymerized material as an emulsion over-
flowing out of the reactor. The emulsion is filtered
continuously to remove large size agglomerates (gels
or "fish eyes").
The filtered material is directed to monomer
recovery where the free monomer is stripped and
returned to the reactor. The stripped suspension
is then separated by centrifugation, followed by a
water wash, dried in a continous oven and stored for
sale to other processors or for captive use. The
precatalyst is recovered. Generally, in multi-plant
operations by a given company, one polymerization
facility services the various spinning plants.
The most important source of wastes is the
filtering process. The waste stream consists of
the polymer itself, sometimes contaminated with
unreacted comonomer.
The monomer recovery still bottoms are essen-
tially water based and are disposed to wastewater
treatment facilities. They contain low molecular
weight polymer, estimated at 7 kg per 1000 kg
produced.
(1) Kirk-Othmer, Encyclopedia of Chemical Technology (2nd Ed.),
Volume I, P. 333, Interscience Publishers, New York (1963).
11-89
-------
FIGURE II-7
ACRYLIC AND MODACRYLIC
FLOW DIAGRAM
Recovered Monomer
Catalyst
Water
Comonomer
Acrylonitrile
Reactor
Recovered
Water and Catalyst
MAJOR
SOLID
WASTES
% TOTAL
PRODUCTION
Offgrade
Products
Still Bottoms
and Waste Oils
Total
0.2
0.7
0.970
Filter
Aqueous
Waste
Dehydration and
Catalyst Recovery
Dryer
Acrylic Resin
I
Fines from
Dust Collectors
Agglomerate
%'aste
Wastewater
Treatment
Sludges
Source: EPA publication EPA-440/I-14-010-a
11-90
-------
3.2.2.2 Polyamides
There are two main polyamide resins
used in fiber production; Nylon 6 and
Nylon 6,6 (Figures II-8 and II-9). Nylon
6 is essentially a polymer of caprolactam,
and Nylon 6,6 results from the condensation
of hexamethylene diamine and adipic acid,
which are reacted to form nylon salt.
There are two ways to polymerize Nylon
6. They differ essentially in how the
unreacted caprolactam monomer is removed.
In the wet method, polymerized chips are
washed with water and the resulting capro-
lactam solution is eventually concentrated,
after treatment with potassium permanganate,
to a 70 percent solution. This final solu-
tion is separated into a bottom stream con-
taining solid oligomers and high boiling
liquids and reasonably pure caprolactam
which is returned to process. Two solid
waste streams are produced: the permanga-
nate residue which is in the form of a
solid and the still bottoms.
In the second, or dry process, the
unreacted caprolactam is stripped from
the molten polymer under vacuum. In this
process, no waste stream is produced,
except for equipment cleanings and ends
of run.
To make Nylon 6,6, hexamethylene dia-
mine is reacted with adipic acid to give a
nylon salt solution which is decolorized
with adsorbent charcoal. The salt is then
mixed with water and acetic acid and poly-
merized in an autoclave with addition of
delusterant (titanium dioxide). The resin
is then band cast, chopped, blended and
stored for shipment or local use in spin-
ning operations.
A significant waste stream consists of
a filter cake, which is a mixture of spent
carbon, diatomaccous earth and nylon salt
from the decolorizing operation, It amounts
to 0.36 percent of the total production.
Some of the wastewater streams from the pro-
11-91
-------
FIGURE II-8
HYLON 6 (POLYAMIDE) FLOW
DIAGRAM
WET MOCESS
W«ier _
C4preUcum
r
NMCtOI
Polymer
Singe
TUtk
K MD O
Wane Wkict f
f Polymer Scrap
' » Nylon 6
•Finet from dun collecton
, Sludges
tecowied Monomer
DRY PKXESS
Cftpiolacum
W«tei T
_.
Vacuum
Snipper
T
Monomer
Recovery
Polymer
Surge
Tudt
- -.» Still Bottonu
Spin
Ptinip
1 0»
1 T
ench
ink
Cuner
Dryer
Nylon 6
L. *. Flra from dud collecton
; Waiet
PotymerScnp
W»ter
TiBftmem
Major
Solid
Wastes
% Total
Production
Off-Grade 0.02
Products
Still Bottoms
and Waste Oils NA
Total
Source Footer D. Soell. Inc.
11-92
-------
FIGURE I1-9
NYLON 6,6 (POLYAMIDE) FLOW
DIAGRAM
Hexamethvlene
Diamine
Water or Methanol
Methancl
Recover,
Aqueous Still ,
Bonoms
Aceuc Acid
Sludges
Nylor Sill
Production
. Decolorants
(Adsorbent)
Adipic Acid
I
*
Waste Adsorbent
(Filter Cable)
Pol.Tnenzauor.
-Delusterant
Off-pade product
Extrusion,
Pelle dung
I
4
Scrap Pellets
Nvlon 6.6 Resin
Wastes
% Total
Production
Off-Grade 0.30
Products
Still Bottoms
and Waste Oils NA
Others
Wastewater
Sludge and
Spent Filter
Coke 0.36
Source Foster D. Snell, Inc., and EPA study (Contract No. 68-01-0030)
Total
11-93
-------
cess contain large amounts (1%) of hexa-
methylene diamine. Though this material
is readily biodegradable in the treatment
facilities, it contributes to the biologi-
cal sludge formed.
3.2.2.3 Polyesters
The polyesters used for fiber production
are glycol terephthalates which polymerize
to polyethylene terephthalate with the forma-
tion of recoverable ethylene glycol (Figure
11-10) . The primary reactant may be the
ester, dimethyl terephthalate, in which
case methanol is evolved during the esterifi-
cation reaction preceding the polymerization.
It is a frequent practice to return the glycol
and methanol streams to the manufacturer. In
this case, whatever still bottoms are associated
with those streams are handled as part of the
glycol or methanol production processes.
The catalysts used in polyester manufac-
ture are reported to include acetates of cobalt,
manganese and cadmium. These catalysts may
obviously give rise to potentially hazardous
waste streams, particularly in primary sludqes
of water treatment facilities. It was not pos-
sible to obtain data on these materials and
no sludge production was reported.
Some manufacturers acknowledge the presence
in their solid wastes of comparatively large
quantities of zinc compounds. But zinc chloride
is widely used as a solution agent for certain
types of solution spinning and this may consti-
tute a larger source of this ion than the
polymerization operations.
3.2.3 Non-Olefinic Polymers Primarily Used As Resins
A series of figures are provided to illustrate the
processes and waste streams discussed under non-olefinic
polymers primarily used as resins.
Phenolic resins—Figure 11-11
Amino resins—Figure 11-12
Coumarone-Indene resins—Figure 11-13
11-94
-------
FIGURE 11-10
POLYESTER RESIN FLOW DIAGRAM
Wastes
Terepbthalic Acid
% Total
Production
Off-Grade
Products 3.00
Still Bottoms
and Waste oils o.Ol
Others
Terephthalic
Acid O.io
Total 3.11
Elhvlene GIvco!
Dimethyl
Terepbthalaie
Water
Polyester Resin
JUJges
Source: Foster D. Snell, Inc., analysis and EPA study (Contract No. 68-01-0030)
11-95
-------
Epoxy resins—Figure 11-14
Alkyd resins—Figure 11-15
Polyurethane—Figure 11-16
Silicones—Figure 11-17
The products in this group are arranged according
to two criteria: production technologies and
production volumes. The first three, phenolics,
amino and coumarone-indene resins, are produced in
specialized, identifiable facilities with rela-
tively large yearly production. Within the group,
the phenolic resins have the highest production
volume. The last group, consisting of resins,
epoxy, alkyds and polyurethanes and silicones
are made in thousands of various formulations,
in hundreds of locations with considerable dif-
ferences in the size of plants, in the sophisti-
cation of equipment used and in the production
technologies. The process descriptions for these
resins are only illustrative. Furthermore, the
significant variations mentioned above make a
generalization of waste stream data infeasible.
3.2.3.1 Phenolic Resins
These resins are formed by reacting
phenol, or a substituted phenol, with an
aldehyde (Figure 11-11). The industry
produces two broad types of resins in this
category: resols and novolaks.
The waste stream from these two processes
consists of partially polymerized material,
containing an excess of phenol, which appears
as a suspension in the water distillates. As
noted later, no satisfactory method of
handling this waste stream has yet been devised.
Some major manufacturers are reportedly at work
on this problem, but consider the development
of such a method to be a highly proprietary item.
3.2.3.1.1 Resol Manufacture
Molten phenol (Figure 11-11) is fed to
the reaction kettle, followed by formalde-
hyde. This serves to clear the lines of
residual phenol. A catalyst solution of
sodium hydroxide is then added and the
kettle heated to about 60°C.
11-96
-------
When the desired degree of poly-
merization has occurred, the kettle is
cooled to about 35°C to inhibit further
reaction. The caustic may be neutralized
in the kettle with sulfuric acid at this
time. The water from this distillation
forms a concentrated waste of unreacted
materials and low molecular weight resin.
The batch is dumped and, depending
on the specific resin, the batch may be
washed several times and a vacuum may be
used during the dehydration cycle. It is
important that molten resin be handled
quickly to avoid its settling up to an
insoluble, infusible mass, which would
become a waste.
3.2.3.1.2 Novolak Manufacture
Novolak manufacture is almost identi-
cal to that of resol (Figure 11-11). The
major difference is that sulfuric acid is
used as a catalyst. Because of this,
vacuum reflex must be used to maintain a
temperature of 85-90°C, which is slightly
higher than for resols. The reaction con-
tinues for 3 to 6 hours at which time the
condensate is switched to the receiver and
water is removed by vacuum. The tempera-
ture goes to about 120-160°C. This
reaction does not have to be cooled
because polymerization is complete.
The product is allowed to solidify
or solvents may be added to keep it in a
molten form. If solidified, it is ground
to powder or flake form before being
shipped.
3.2.3.2 Amino Resins Manufacture
When formaldehyde is reacted with certain
nitrogen containing organic chemicals, in par-
ticular urea and melamine, an amino resin is
formed (Figure 11-12). Typically, amino resins
are manufactured in a standard batch polymeri-
zation process. Because many specialty grades .
are made, the batches are frequently small.
11-97
-------
FIGURE 11-11
PHENOLIC RESIN FLOW DIAGRAM
Phenol
Catalyst
Formaldehyde
Weigh
Tanks
Vacuum
System
Condenser
Reactor
Receiver
Off-grade
Product
Waste
Wastewater and
Unreacted Chemical*
% Total
Production
Product Resin
Off-Grade
Products 0.8
Still Bottoms
and Waste Oils 3.8
Others
Wastewater
'Sludge 6.0
Total 10.6
(1)
Dry Basis
Source: EPA publication EPA-440/l-74-010-a
I-r
-1 -
-------
FIGURE 11-12
AMINO FORMALDEHYDE RESIN FLOW
DIAGRAM
Formaldehyde
Boric Acid
Sodium
Hydroxide
JL
Urea or
Melamine
Weigh
Tanks
Vacuum
Tanks
Condenser
Reactor
Receiver
Off-grade
Product
Wastewater and
partially poly-
merized material
Rerin Syrup to
Storage or
Drying
Wastes
Off-Grade
Products
% Total
Production^
1.0
Still Bottoms
and Waste Oils
1.2
Source: EPA publication EPA-440/l-74-010-a
Others
Filter Coke
0.24
Total
(1)
Illustrative Data
Only
5.44
11-99
-------
Formaldehyde is put in the kettle and the
pH adjusted to about 7.0-7.8. The catalyst,
boric acid, is added and then the urea or
melamine. The pH is adjusted again to near
neutral. The reaction proceeds at lOQOG under
atmospheric reflux conditions for about 2 hours.
Then, a vacuum is applied and the temperature
dropped to 40°C for about 5 hours. The system
is then put on total reflux and the pH adjusted
to slightly alkaline. The material may either
be shipped as a liquid or dried and powdered.
In some instances, formaldehyde is received
in a pure state. In this case, there is a
tendency for solid formaldehyde polymers to
be produced—para-formaldehydes. These are
highly flammable solids, giving off strong
formaldehyde fumes. Bad batches, containing
large excesses of unreacted formaldehyde,
require disposal.
3.2.3.3 Coumarone-Indene Resins
The name of this group of resins is somewhat
misleading. Initially, these resins were con-
densation products of a coal tar fraction con-
sisting essentially of coumarone and indene.
At present, the bulk of the production is based
on the condensation of various reactive chemi-
cal species present in heavy petroleum distillates
(boiling point in the range of 100°C to 250°C).
In summary, there are two groups of raw
materials:
C-I crudes (coumarone-indene fraction
of coal tar distillates)
Petroleum distillates.
Lighter fractions of petroleum distillates
are used in the process as a diluent.
Coumarone-indene resins are manufactured
by two basic methods:
Thermal polymerization
Solvent polymerization.
11-100
-------
In thermal polymerization (Figure 11-13) ,
the raw materials are blended to a predetermined
composition, then heated under pressure. After
the polymerization has reached the desired
point, the reaction is vented to a condenser
where a distillate (sometimes called "inert")
is recovered. The batch is then steam stripped
under vacuum until the desired hardness is
achieved. The resin is then transferred to
packaging kettles.
The solvent process (Figure 11-13) may
take two forms depending on raw materials. If
the C-I crudes are used as the starting material,
acid and caustic washes are required to remove
amines and phenols which are present in the
crudes. This procedure is not required if
petroleum distillates are the raw material.
This is the only difference between the two
forms.
A polymerization catalyst is used. It is
usually boron trifluoride. The mixture is then
heated until the desired degree of polymeriza-
tion is achieved. At this point, additional
diluent and a mixture of attapulgite clay
and lime are added to the reactor. The mass
is then filtered in a continuous vacuum filter
to remove the clay and lime.
The filtrate undergoes fractional distilla-
tion. The low boiling fractions are recycled
as diluent or burned as boiler fuel. The
middle fractions constitute the desired product
and the still bottoms are sold as a lower grade
product.
The waste streams from these operations are
the clay/lime cake, which may contain some
fluorine and some boron, and the products from
wastewater treatment. In most installations,
the wastewater treatment includes a trap which
collects the waste oils. These are used as fuel
for the boilers. The final wastewater treatment
consists of carbon adsorption. The spent
carbon is returned to the supplier for regenera-
tion. The amount of carbon and oily wastes
varies according to the product mix. The waste
clay/lime residue is a function of the amount
of resin produced by the solvent process.
11-101
-------
FIGURE 11-13
COUMARONE-INDENE FLOW DIAGRAM
THERMAL PROCESS
Raw Materials (C-I crudes and/or distillater)
Light Ends
Blending
1
r
Polymerization
~1
^
r
Steam Stripping
Steam '
% Total 1
Wastes
Production
r
Packaging Kettles
4
Q "In*:
aj? (solvent
n c
B> c
it
(see solv
Eation
r
:f
: or boiler i
eatment
'ent process)
Off-Grade
Products
Still Bottoms
and Haste Oils
Others(spent
clay)
Total
NA
NA
3.6
I
Finished Product
SOLVENT PROCESS
CI - Crudes
Acid Wash
Caustic Wash
—^ Amines —
^ Phenols _
Carbon
Carbon to be
Regenarated
T
Oily Haste
(Boiler Fuel)
Petroleum Distillates
Solvent
Polymerization
Dilution
Boron Trifluoride
Attapulgite Clay & Lime
Filtration
— fr- Clay t Liae
Light Ends
Fractionation
* Still Bottoms
(Lower grade material
sold at a discount)
Boiler Fuel
Finished Product
11-102
Source: Foster D. Snail, Inc.
11-102
-------
3.2.3.4 Epoxy Resins
The bulk of the epoxy resins are produced
by the condensation of epichlorohydrin with
bisphenol A (4.4'-isopropylidenediphenol).
However, formulation variants involve the use
of other polyols, i.e., aliphatic glycols.
Sometimes epichlorohydrin is reacted with
Novolak type phenolic resins, thus transform-
ing them into epoxy type products.
The final desired properties are obtained
by achieving a combination of basic resin
formulation of the degree of polymerization
desired and of curing agents. These are
added at the point of use, so that the final
products are made by mixing a resin component
with a curing component, very often in equal
or nearly equal volumes. The curing agents
cover a broad range of chemical species:
amines, polyamides, acids and anhydrides, or
even resins of the phenolic or the polyamino
groups.
The bulk of the commercial production is
in the so-called lower molecular weight group
(M.W. 360-650) which is liquid at room tempera-
ture. Higher molecular weight material has
a consistency varying from "taffy" (M.W. 800-
1,000) to brittle solid (M.W. 2,000-8,000).
The highest molecular weight material (M.W.
5,000-8,000) melts at 145-155°C.
The production processes vary enormously
in technology and capacity. The processes
described in the following paragraphs are only
illustrations. The formulations of the cata-
lysts, which are used to promote the desired
straight line reaction over an undesirable
branching type of reaction, are highly pro-
prietary.
3.2.3.4.1 Continuous Process
The process described here (Figure
11-14) is a two-step process. Bisphenol A,
epichlorohydrin, catalyst and 50% caustic
soda solution are continuously fed at
appropriate rates to a first polymerization
chamber. The material then passes continu-
ously to epichlorohydrin removal where
11-103
-------
FIGURE 11-14
EPOXY RESIN FLOW DIAGRAM
(CONTINUOUS PROCESS)
Bisphenol A_
Epichlorohydcfal
50% Na OH
Catalyst
i
Storage
*
Dusts
Tanks
Storage
Tanks
'
1st
Polymerization
1
Epichlorohydrin
Removal
1
2nd
Polymerization
Methyl
Isobuty
Ketone
(Solvent)
Water _
1
yl ~^"
Storage
Tanks
Solvent
Washing
I
i
Solvent
Removal
Hattewater
Treatment
\
Haste Phase
Rejected Polymer
Waste
Waste
Epoxy Resin
^ Sludges Products
% Total
Production
Still Bottoms
and Waste Oils
Others
Total
NA
NA
NA
Source: EPA publication EPA-440/I-74-010-a
11-104
-------
excess epichlorohydrin is removed and
returned to the storage area. The
material stripped from epichlorohydrin
goes to a second polymerization chamber,
where an additional amount of 50%
caustic is introduced at the appropriate
rate. The material leaves the chamber
to go to a washing operation where water
and methyl isobutyl ketone are added
to provide a two-phase system which is
continuously separated, the water phase
being discarded. A final step consists
of solvent removal. The solvent is then
recycled to the washing operation. The
waste streams in this process are unusable
off grade product and wastewater which
usually has to be treated by a conventional
treatment system.
3.2.3.4.2 Batch Process
In this variant of the process, the
operations of first and second polymeriza-
tion, epichlorhydrin removal, washing and
solvent removal are carried out successively
in the same vessel. However, in this
case, at the end of the operations the
temperature is such that the resin is in
the molten state at between 7QQC and 150oc.
This process is sometimes referred to as the
batch fusion process. The molten resin
is allowed to solidify and then can be
flaked or ground to a powder. The waste
streams are the same as in the continuous
process. Proprietary catalysts are believed
to be discarded in solution in the wastewaters
3.2.3.5 Alkyd Resins
Chemically, the alkyl resins are the products
of the reaction (esterefication) of various poly-
hydric alcohols (polyols) with holy basic acids
(e.g.), phtalic or malic acid) and unsaturated
aliphatic acid (fatty acids).
Alkyds are made generally in liquid form
and are further compounded and modified at
their point of use. There are innumerable
formulas and ingredient combinations.
11-105
-------
Individual production units are usually
quite small and often associated with larger
manufacturing facilities, principally in the
paint and coatings industry SIC 285.
The problem with this particular group
of polymers is that the esterification reaction
between acid and hydroxyl (alchol) groups
(-CHOH and -COOH) releases a mole of water.
Since the reaction is reversible, this water
has to be removed to allow the reaction to
continue to proceed in the desired esterifica-
tion direction. Two main processes (Figure
11-15) are used to achieve this end:
In the solvent process, the reactants
are introduced into a polymerization
kettle. A solvent, such as xylene, is
continuously added to the kettle and
allowed to distill out as an azeotrope
carrying the water vapor. In a solvent
recovery unit, the water is separated
as an aqueous stream and the solvent
returned to the kettle.
After completion of the polymerization,
the resin is thinned with a solvent
(xylene) in a thinning tank and the
mixture is filtered to remove solid
waste (off grade product).
In the dry process, also known as fusion
process, the materials are introduced
into a polymerization kettle, a stream
of inert gas is sparged through the mix-
ture to carry out the water vapor formed.
When polymerization is complete, the resin
is transferred to a thinning tank, sol-
vent is added and the mixture is filtered.
3.2.3.6 Polyurethanes
Polyurethanes are obtained by reacting
di-isocyanates or polyisocyanates with polyols
or polyamines (Figure 11-16). Many of these
reactions can be carried out at the point of
use in completely unsophisticated equipment
amounting to little more than a kettle with
a stirrer. Formulations encompass literally
thousands of varying combinations of ingredi-
ents, mostly proprietary.
11-106
-------
FIGURE 11-15
ALKYD RESIN FLOW DIAGRAM
SOLVENT PROCESS
Solvent Recovery
Aqueous Steam
Mcohol
Fatty Acid
Potybaric Acid
t
Still Bonomt
Polymerization
Xytene
J ;
Off-grade product
Thinning Tank
Filter
Xyene
Solvent
Alkyd Resin
Solid Product
waste
Hastes
DRY PROCESS
Inen Gas Sparge Line
Off-Grade
Products
Still Bottoms
and Waste Oils
Polybaiic Acid _
Polybydric Alcohol.
Farry Acid
f- — -»«-Water Vapor & Inert Gas
J_
Polymerization
Solvent
Thinning Tank
Others.
Swei
epangs
_ ^ _ t Off-Grade Productt
% Total
Production^)
Total
Illustrative data only
*~. Alkyd Reiin
Solid Product
uuic
0.10
0.01
Source Focter D. Snell. Inc.
11-107
-------
FIGURE H-16
POLYURETHANE FLOW DIAGRAM
Uocyanate
Heating
Poly hydroxy Compound
. Vacuum
' ^2
Reaction
Cool to maintain
temperature
, Off-grade
Product
Cooling
Drumming
Vent to Scrubber
Source Foster D. Snell. Inc.
11-108
-------
The only production of polyurethanes
by SIC 2821 appears to be that of "pre-
polymers." These prepolymers are complex
mixtures of partially polymerized products
and usually of highly proprietary formulation.
The prepolymers are classified as reactive
and non-reactive. These names refer to the
subsequent steps necessary to complete poly-
merization. Reactive prepolymers can poly-
merize by action of atmospheric moisture.
The mechanism of polymerization of the non-
reactive prepolymers can be straight air
oxidation or may require the addition of a
reactant mixture.
Most of the production is carried out
directly from the monomers (often referred
to as compound A and compound B) by plants
outside the SIC 2821. For instance, pro-
duction is carried out by automotive accessory
manufacturers (cushions, padding), by paint
plants or by appliance manufacturers (i.e.,
refrigerators). In addition, the global
production figure is only about 50,000 KKg
per year (100 million Ibs./year).
3.2.3.7 Silicones
Silicone rubber and resins are made by
the polymerization of several silicone mono-
mers or oligimers. The backbone of the
polymer is based on Si atom(s) rather than
on C atom(s). The silicones are usually
manufactured in extremely complex plants,
which often incorporate in their operation
the production of the monomers themselves.
In addition, the products of polymerization
are arbitrarily classified between segments
2821 and 2822 of the SIC 282 group and
segment 2869 of the SIC 286 Industrial Organic
Chemical Industries.
Silicones are produced in only a few
plants in the United States. The production
methods, processes and even products and
by-products are highly proprietary.
11-109
-------
The process descriptions and flow
diagrams presented in this study represent
information developed by direct discussion
and interviews with industry representatives
and are limited by considerations of possible
inadvertent disclosure of confidential infor-
mation.
In very general terms, there are two
initial parallel operations resulting in
products classified in SIC 2821 and 2822:
A bulk polymerization step producing
gums and hydrolyzed silanes
An emulsion or suspension polymeriza-
tion process producing silanol fluids.
In addition, there are further processing
operations:
The gums produced by bulk polymerization
are compounded as silicone rubber plastics.
The gums are disposed in solvent and
marketed as dispersion (plastisols).
Further processing of by-product streams
of bulk polymerization leads to the produc-
tion of room-temperature vulcanizing
rubber (RTVR) .
An alternative route leading to silicone
resins starts with chlorosilane compounds. These
compounds are hydrolyzed in a reactor containing
water and an immiscible solvent. The water
layer containing hydrochloric acid is discarded
and the solvent layer containing the hydrolyzed
silanes is polymerized to silicone resins by
addition of catalyst and heating. Figure 11-17
summarizes the process involved.
The following descriptions are illustrative
and are intended to key some reported waste
streams, the exact origin of which is proprie-
tary.
11-110
-------
FIGURE 11-17
SILICONE PRODUCTS FLOW
DIAGRAM
mice-OBgomen
Caulyn
Witer
CUorodltnu
I Solvent
Off-Gride
Iwan
I
Hydrolyiti
Kettle
HC1 to Recovery
Dbpenion
Sllicooe Mibtaer
Compound!
Room Temper»ture
Vulcanizing Rubber
--+. wttte
Solvent
Addldves
__,». Filler C»ke
StUcone fteiln
Wane Wtter
Tieatmcnt
^_ Sludges
Wastes
Off-Grade
Products
% Total
Production
5.4
Still Bottoms
and Waste Oils
5.8
Spent Adsorbent
and Scrap 3. 3
Total 14.5
Source: Foster D. Snell, Inc.
11-111
-------
3.2.3.7.1 Gum Production
Silicone gum is produced by poly-
merization of a mixture of silico-oligomers
in the presence of a catalyst. Volatile
compounds are evolved during the operation
and are partly returned to the process after
condensation and partly disposed of as
liquid wastes. Prior to being fed to the
reactor, some of the oligomers are dried
by adsorption on silica gel type molecular
sieves. These are discarded from time to
time giving rise to a waste stream. Clean-
ings of the equipment and off-grade unusable
products are also disposed of. The product
gums are used as raw materials for the
production of silicone rubber.
3.2.3.7.2 Silicone Rubber Compounding
One type of silicone rubber is produced
by compounding gums, additives and fillers
on a Banbury mixer. The product is further
compounded (refined) on roll mills. These
operations produce a liquid waste stream and
a solid waste stream.
3.2.3.7.3 Silicone Resin Production
The starting materials for this produc-
tion are a mixture of chlorosilanes and
solvent. The first step involves the
hydrolysis of the chlorosilane by addition
of water. This is followed by gravity
or centrifuge separation of the water
layer. The next step is the polymerization
step, sometimes called bodying. This
step is carried out in an agitated kettle
with addition of a catalyst (sometimes a
salt of zinc) and by heating. The solvent
is then stripped off and usually disposed
of as waste. At this point, some resins
are simply cooled and flaked. Other resins
are obtained by addition of various proprie-
tary ingredients. When the additives
have dissolved, the resin is filtered over
filter presses and allowed to cool. The
waste streams in this process are, in addi-
tion to the waste solvent already mentioned,
the filter cake and some scrap resin—either
off-grade product or from cleaning the
reactors.
11-112
-------
3.2.4 Cellulosic Products
Chemically, there are two fundamental groups
of cellulosic products: the rayons and the acetates.
At present, the bulk of the production of these
materials is for fiber manufacture. However, there
is still a significant production for films (cello-
phane and photographic films of acetate). The
rayons are basically reconstituted cellulose. The
acetates are reaction products of cellulose with
acetic anhydride. The most recent form is known
as the triacetate. In the U.S. the term "rayon"
includes man-made textile fibers and filaments
composed of regenerated cellulose. The term
"acetate" has been adopted to indicate man-made
textile fibers and filaments composed of cellu-
lose acetate.
3.2.4.1 Rayon
Chemically, rayon is a modified cellulose,
which is the main constituent of wood pulp. Since
1910 to 1911, the rayon in the United States has
been produced by the Viscose process (Figure 11-18).
Wood pulp (pulp) is slurried in a caustic solution
(NaOH), then the excess caustic is expressed and
goes to a dialysis step to separate the hemicellu-
lose formed by reaction of caustic with some
of the cellulose. The treated caustic solution is
returned from the dialysis to the steeping operation.
The treated pulp from the steeping process goes
to a shredding operation which forms crumbs. The
crumbs are aged in the crumb aging operation
under controlled conditions. The crumbs are reacted
in a churn with aqueous NaOH (dilute caustic) and
carbon disulfide (CS2) to form cellulose xanthate.
Proprietary additives are added in a mixer and a
secc-nd aging process takes place. Then, the slurry
goes to a deaeration step, followed by a filtering
step, and a viscose solution is obtained that can
be used for a casting operation to form cellophane
on a spinning operation to form fibers.
The waste streams from this operation consists
of solutions of hemicellulose and a solid waste,
which is in effect an off-grade product. Difficul-
ties in meeting water effluent guidelines have
resulted, and continue to result, in the decline
of rayon production in the United States. Numerous
large production facilities have been closed down.
11-113
-------
Na OH Makeup Pulp
Dialysis
1 L
Steeping
Hemicellulose Waste
In Water
Shredding
Crumb Aging
Aqueous Na Oti
Chum
Additives
Mixer
Aging
Deaeration
Filter
Waste Water
Treatment
.Sludges
FIGURE 11-18
VISCOSE RAYON FLOW DIAGRAM
CS,.
I
I
t
Solid Insoluble Waste
Viscose
Source EPA publication EPA-440/I-74-010- a
11-114
-------
3.2.4.2 Acetates
There are two basic types of acetates
produced in significant quantities. These
materials differ only in the degree of ace-
tylation. When 92% or more of the hydroxyl
groups in cellulose are acetylated, the prod-
uct is referred to as cellulose acetate. There
are no significant differences in the manu-
facturing processes of these materials. A
flow diagram of the process is presented in
Figure 11-19.
After shredding, the wood pulp goes to the
acetylation process where it is treated first
with acetic acid to activate the cellulose.
This is then fed to acetylation reactors where
it is treated with acetic anhydride. A clear
viscous solution of cellulose acetate in water
is obtained.
The product is recovered as a flake by
precipitation with a weak acetic acid solu-
tion and countercurrent water wash. The
flakes are dewatered on a vibrating screen
and dried in an oven. The water stream from
the vibrating screen is filtered and the
filter cake is returned to the head of the
process; therefore, a waste is not created.
The filtrate is sent to acetic acid recovery.
The acid recovery is performed by extractive
distillation with a proprietary solvent.
The still bottoms include a concentrated
solution of magnesium sulfate, soluble cellu-
lose products and a trace of the solvent.
3.2.5 Spinning Processes
Spinning operations are significantly different
from the polymerization processes described in the
previous sections. Spinning differs from poly-
merization both in terms of the equipment used and
the type of physico-chemical changes occuring. In
many instances, a form of further polymerization
takes place; however, this polymerization is in the
form of cross-linking. Cross-linking is similar
in chemical terms to the vulcanization of rubber
which is discussed in Volume III of this report.
11-115
-------
Cellulose
(Wood Pulp)
FIGURE 11-19
CELLULOSE ACETATE RESIN FLOV, IMA CRAM
Shredding
Glacial Acetic
Acid
Filter Cake
Acetylation
Precipitation
Wash, Dry
Acid Recovery
Cellulose Acetate
Flakes
Acetic
Anhydride
.Weak Acetic Acid
.Water
I
I
t
Wastewater
(Still Bottoms)
Wastewater
Treatment
Sludges
Source EPA study (Contract No. 68-01-0030)
11-116
-------
Fundamentally, spinning is an extrusion
process (Figure 11-20) in which the polymer is
forced through spinnerets either in solution
form or as a melt. The spinning operation may
also be an extension of the basic polymerization
process. When the polymer is in solution form,
it is called a dope. The solvent can be water,
an aqueous salt solution or a water miscible
organic liquid.
There are three basic spinning methods:
Melt spinning where the extruded fiber
solidifies by cooling
Wet spinning in which the fiber solidi-
fies by coagulation in a bath
Dry spinning where the fiber solidifies
by evaporation of the solvent.
Subsequent treatment may involve stretching,
washing, bleaching, lubricating, crimping and
dyeing. The order of these steps varies accord-
ing to the products treated and the result
desired.
Spun fibers include monofilament (a single,
untwisted synthetic filament) and yarns, staples
and tow. Staple and tow are produced by chopping
the fibers to desired lengths. Staple in general
has shorter fiber lengths than tow and is used in
further spinning operations characteristic of
typical textile operations. Tow is used in such
applications as filters for cigarettes. Mono-
filaments and yarns are directly processed into
fabrics, ropes, etc.
A synoptic presentation of spinning processes
is provided in Table 11-38 for the most common
fibers. Processing steps and wastes generated are
discussed in greater detail in the following para-
graphs for each of these fibers. The discussion
is organized in the order of production volume.
11-117
-------
POLYMER
DRY
MELT
SOLVENT
SPINNING
DOPE
MOLTEN
POLYMER
WET
EXTRUDER
H SPINNING
7 CELL
M
M
CD
FILTER
I
SPINNERET
EFFLUENT
->AIR G SOL-
VENT
FILTER
METALLIC
SALT _|
SOLUTION
1
T
SPINNERET
INFLUENT
AIR
TRANSVERSE
AIR FLOW
CURRENTS
TO
SOLIDIFY
FIBERS
FIBER WINDING
FIBER WINDING
FIGURE 11-20
SPINNING PROCESS FLOW DIAGRAM.
SPINNING DOPE
FILTER
SPINNERET
SPINNING
BATH
PURIFICATION
WATER &
DIMETHYL FORMAMIDE
,4—SULFURIC ACID
.4-SODIUM SULFATE
h-ZINC SULFATE
CHEMICAL
RECOVERY
DRYING AND
PRE-SHRINKING
1
FIBER
WINDING
-------
TABLE 11-38
SYNOPTIC DESCRIPTION OF SPINNING PROCESSES
Fiber Method
Hayor. Wet spinning
Polyester Melt spinning None
Acrylic Fiber
Nylon
Modacrylic
(Dynel)
Dry spinning
Melt spinning
Wet spinning
Solvent
Water
Bath
Water solution of
sulfuric acid,
sodium and zinc
sulfate
Secondary
Bath
Dilute acid
Further
Treatment
Stretching - water
washes, drying
Bath Reclaim
Evaporation, crystalli-
zation , composition
correction
Cellulose
Acetate
Cellulose
Triacetate
M
M
1
Dry spinning Acetone
Dry spinning Methanol and
methylene
chloride
Solvent
None
Cool air
Hot air to evaporate
solvent
Hot air to evaporate
solvent
Wet spinning Water miscible Water
solvent
Hot air to evaporate
solvent
Cool air
Water
Finish application
Water wash
Finish application
Water
Stretching, crimping
Fiber lubrication
Fiber lubrication
Steam stretching
spin finish, crimping,
setting
Carbon adsorption, steam
stripping, distillation
Carbon adsorption, steam
stripping, distillation
Distillation to recover
solvent
Carbon adsorption, steam
stripping, distillation
Steam or hot water
stretching
Finish application,
5 to 15 times stretch-
ing , annealing, crimping
Distillation
Source: Foster D. Snell analysis of literature data.
-------
3.2.5.1 Polyester And Nylon Spinning
The same process (melt spinning) is used
for the spinning of polyester and of nylon
fibers. The polymers (polyester and nylon) are
produced by the processes discribed in the
previous subsections dealing with polyester
and polyomide production.
The polymer is heated to its melt point
and filtered through sand or metallic filters.
The filters are directly ahead of the spinnerets
through which the filtered melt is extruded.
The extruded melt is cooled under controlled
conditions, and solidified fibers form subse-
quently.
Polyesters are dry stretched while nylon
is stretched in steam or hot water baths. Some-
times, the fibers are crimped and vegetable
oil finishes may be'applied.
The wastes generated by this process are
mostly represented by off-grade material. In
many cases, this waste may be depolymerized
or returned to the polymerization processes.
For example, terephthalic acid can be removed
from off-grade polyester fiber and returned to
production. Filtering sand is also a waste.
Metallic filters in most cases do not
represent a significant waste because they
may be regenerated via highly proprietary
techniques.
3.2.5.2 Acrylics
There are two methods which can be used
for the spinning of acrylic fibers: wet
spinning and dry spinning.
Wet spinning involves two variants:
In one, the resin is dissolved
in concentrated solutions of
mineral salts. Here, the coagu-
lation process consists of leach-
ing out the metal salt(s) from the
spun fiber by means of water baths.
The salts are usually recovered.
11-120
-------
In the other variant, a water
miscible solvent, for example
dimethylformamide, is used to
prepare the spinning dope. The
solvent is leached out by water
baths.
The dry spinning process involves the
use of an organic solvent. A recovery
step is required. Recovery steps usually
involve adsorption of the solvent on
activated carbon followed by steam strip-
ping of the saturated carbon and final
recovery by distillation or decantation.
From time to time, the carbon beds are
replaced. If a significant stream is thus
generated, the carbon is returned to the
manufacturer for reprocessing. In the case
of spinning from a metal salt solution, the
metal ions eventually end up in the wastewater
treatment sludges. One of the principal salts
thus used is reported to be zinc chloride and,
therefore, the wastewater treatment sludges
contain significant amounts of zinc.
Subsequent steps may involve steam stretch-
ing, dyeing, finishing, crimping and settling.
No significant wastes are generated.
3.2.5.3 Modacrylics Spinning
Modacrylics differ from acrylics chemically
because they are copolymers.
The process used to spin the modacrylic
fibers are similar to those used for acrylics
and may indeed use the same equipment at
certain locations. As an example, the spinning
of Dynel is discussed here.(D
Dynel is a copolymer of acrylonitrile and
vinyl chloride prepared by the emulsion pro-
cess described in paragraph 3.2.2.1. The
(^Kirk-Othmer, Encyclopedia of Chemical Technology, 2nd Edition,
Volume 17, pp. 168-209, Intersciences Publisher, New York
(1967) .
11-121
-------
resin is dissolved in acetone and extruded
through a spinneret into an aqueous coagu-
lating bath. After washing to remove the
solvent and after the application of a
finish, it is stretched from five to fif-
teen times its original length. Next, the
fiber is annealed or baked by exposing the
yarn to hot circulating air. This treat-
ment relieves strain and reduces subsequent
shrinkage. Finally, the fiber is crimped,
cut and baled.
Off-grade material constitutes the only
significant waste streams generated in spin-
ning of modacrylics.
3.2.5.4 Rayon Spinning
The rayon is manufactured by the process
described in section 3.2.4.1, in the form of
a solution of cellulose xanthate. This solu-
tion, after filtration and deaeration, is
pumped through spinnerets into a coagulation
bath consisting of a solution of sodium sul-
fate and magnesium sulfate acidified with
sulfuric acid. There are, however, numerous
variants in the composition of the xanthate
solution and of the bath, which are used to
improve the characteristics of the finished
product.
The solidification of the rayon fiber
in the coagulation bath is a two-step process.
As the cellulose xanthate coagulates, there
is an accompanying chemical transformation
from the xanthate salt to pure cellulose.
This is called regeneration and it precedes
coagulation.
The net effect of the addition of chemi-
cals to the xanthate solution and/or to the
bath is to increase the time lag between these
two steps, resulting in an improved tenacity
of the fiber. Among the additives reported
in the literature are substituted ethylene
diamines and dithiocarbamates. Metallic salts,
such as zinc chloride, #re also used as addi-
tives. ( '
(^Kirk-Othmer, Encyclopedia of Chemical Technology, 2nd Edition,
Volume 17, pp. 168-209, Intersciences Publisher, New York
(1967).
11-122
-------
The complex nature of the bath associated
with the spinning of rayon requires extensive
water treatment facilities. The mineral salts,
such as zinc chloride, are precipitated out
as sludges. These sludges constitute the
main waste stream from rayon spinning and
may contain leachable metal ions.
Other waste streams that are generated
consist of off-grade material which
is discarded or returned to the head of the
viscose production stream.
3.2.5.5 Cellulose Acetate And Triacetate
Spinning
Cellulose acetate and cellulose triace-
tate fibers are produced by a dry spinning
process. In this process, cellulose acetate
or triacetate, prepared by the process described
in section 3.2.4.2, is dissolved in a solvent
to form a dope.
In the case of cellulose acetate, the
solvent used for the manufacture of the
dope is acetone.
In the case of triacetate, the best
solvent is a mixture of methanol and
methylene chloride.
The dope is then spun through a spinneret, as
shown in Figure 11-20.
The solvents are evaporated from the
spun material by means of a hot air stream
and adsorbed on carbon. The evaporated
solvent is regenerated by steam stripping of
the saturated carbon followed by distillation.
No waste stream is generated by solvent recovery.
The only further processing step is reported to
be fiber lubrication.
The wastes associated with spinning opera-
tions are shown in Table 11-39.
11-123
-------
TABLE 11-39
SUMMARY OF WASTE FACTORS IN THE
SPINNING OPERATIONS AS A PERCENT OF TOTAL
PRODUCTION — SICs 2823 and 2824
Waste Factors As A Percent of Total Production
I
H
N)
Product Method
Polyester Melt
Polyamides
Nylon 6 Melt
Nylon 6,6
Off-Grade
Product
4.0
4.0
0.5
Waste Water
Sludges
None Reported
None Reported
None Reported
Finishing
Oils
0.7
None Reported
0.17
Others
Sand "Filter 0.02
Polymer 1.0
Lube Oil 0.07
Acrylics
Cellulose
Acetate
Wet
Dry Spinning
5.0
0.2
20.0<1><3>
None Reported^)
Not individually
reported
Rayon
20.0(3)
(1)
This represents a sludge production typical of a salt solution process.
'2'A considerable array, of products was manufactured at the sites inspected, and there was no way
to separate the contribution of the waste streams to waste treatment sludges.
*•*)These streams are designated potentially hazardous.
Source: Foster D. Snell, Inc., analysis of industry interviews and literature information.
-------
4. WASTE CHARACTERIZATION FOR THE PLASTIC MATERIALS AND
SYNTHETICS INDUSTRY
For the purpose of waste characterization, no valid reason
exists to maintain the SIC segmentation of SIC 282. A more
reasonable segmentation is between the polymerization and the
spinning operations since these topics are more descriptive
of the actual conditions in the industry.
The previous section described the processes used and waste
streams generated in the segments of SIC 282. The present section:
Identifies and quantities general waste streams
found in our industrial analysis through field
visits, interviews and literature studies.
Pinpoints the streams which have been found to be
potentially hazardous.
Quantifies the wastes for the years 1974, 1977
and 1983.
Qualification of waste streams were presented in Table 11-37 for
the polymerization operations and in Table 11-39 for the spinning
operations.
4.l Waste Stream Characterization In Polymerization Operations
The identification and quantification of the waste streams,
particularly in an industry group like SIC 282, is complicated
by several factors. Some of these factors are as follows:
Location of the production facilities — e.g.. single
or integrated, and, if integrated, with that
Relative importance of the process at a given
location of the production facilities
Unquantifiable and variable distribution of pro-
ducts among various production processes — e.g.,
emulsion and solution SBR
Unquantifiable and variable distribution of raw
materials in such groups as epoxy, alkyds,
polyurethanes, silicones.
11-125
-------
Another important factor is the presence of two types
of waste streams:
Well-defined waste streams bearing a fairly
constant quantitative relationship to the
production volume, e.g., still bottom
Fortuitous waste streams, characterized by a
lack of consistent magnitude, composition, and
dependency on extraneous factors, e.g., product
changes, human errors, instrument failures.
The field study indicated that the fortuitous waste
streams constitute the bulk of the streams, both in number
and degree of importance. For instance, it was found that
a very important waste stream was that of the irrecoverable
off-grade product. The sources of this stream include
ends and beginnings of runs, reactor cleanings, spillages,
and production upsets.
Further complicating the characterization of some waste
streams is the highly proprietary nature of some of the
materials involved. In certain product groups (e.g., alkyds
epoxy resins, acrylics, and modacrylics), the monomers
themselves are proprietary. Almost invariably the exact
nature of the catalysts cannot be divulged. Spinning bath
compositions are also proprietary.
Within these restrictions, a review of the individual
waste streams reported by the interviewees during the field
visits is presented in the following paragraphs. The
order of presentation is according to decreasing production
volume of the particular group of polymers. Subcategories
(e.g., polyvinyl acetates) are discussed with the main group,
regardless of their individual production levels.
4.1.1 Polyesters
The bulk of polyester production is for use in the
fiber industry. Much of the production is captive.
The polyesters most widely used are glycol
terephthalates, which polymerize to polyethylene
terephthalate with production of ethylene glycol as
a by-product (Section 3.2.2.3 Figure 11-10; Process
Flow Diagram). The ethylene glycol is either processed
at the polymerization site or returned to the supplier.
In many instances, the primary reactant may be dimethyl
terephthalate, in which case a by-product of methanol
is produced by transesterification. Usually, this also
constitutes a valuable stream which is returned to the
supplier.
11-126
-------
The literature(1) indicates the use of acetates
of cobalt, manganese or cadmium as catalysts. How-
ever, the published flow diagrams do not involve a
catalysts removal step, nor have any of the inter-
viewees reported such a step. Wastewater treatment
facilities are incorporated at most production loca-
tions and the metallic ions associated with the
process may appear in the sludges.
Some manufacturers indicate the presence in
their solid wastes of large quantities of zinc com-
pounds. However, zinc chloride is used as a solution
agent for certain types of wet spinning operations,
and this may constitute the largest source of zinc
ion. It is to be noted also that polyesters, as
esters, are readily hydrolyzed so that depolymeriza-
tion of off-grade waste products are returned to
production.
Other wastes include off-grade products still
bottoms, waste oils and unreacted terphthalic acid.
4.1.2 Polyamides
The waste stream from Nylon 6 production (Section
3.2.2.2, Figure II-8) consists of manganese hydroxide
mud from purification of the recovered caprolactam
stream and the still bottoms from caprolactam dis-
tillation.
The main waste stream from Nylon 6.6 (Section
3.2.2.2, Figure II-9) production is the spent carbon
from the decolorization step. Another stream con-
tributed to by this operation is the biological sludge
formed as part of the biological degradation of hexa-
methylene diamine, one of the starting materials.
Off-grade products may account for 3 Kg/KKg of pro-
duction (0.3%).
(1) Kirk-Othmer, Encyclopedia of Chemical Technology (2nd
Edition), Vol. 16.
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4.1.3 Acrylics And Modacrylics
In acrylic production (Section 3.2.2.1, Figure
II-7), the main waste stream (agglomerate wastes)
results from filtration after the polymerization
reaction has taken place. The waste can contain
large particulates of the polymer referred to as
gels or "fish eyes." Monomer recovery still bottoms
are another source of waste. These wastes are aqueous
and are treated in the wastewater treatment facilities,
They may contribute oligimers to the wastewater sludge.
The operation at one specific plant is said to
involve a moderately toxic metal ion which is pre-
cipitated as a primary sludge. To disclose the ion
or the operation would, however, be contrary to the
competitive interests of the interviewee.
4.1.4 Low Density Polyethylene
The production technology of this product
(described in Section 3.2.1.2.2) is reasonably uni-
form. The only waste streams identified are:
Spent lubricating oils from the compressors,
which may be found in other polymerization
and spinning processes
Oligomers from the monomer recovery
Off-grade products, which may amount to 1.0%
(10 Kg/KKg of production.
The production does not involve the use of
identifiable catalysts.
4.1.5 High Density Polyethylene
The variation of the processes used in the
production of polyethylene resins contributes to
the difficulty in quantifying the waste streams.
It is known that the bulk of the high density
polyethylene is still manufactured by variants
of two solution processes: the Phillips process
and the Ziegler process (Section 3.2.1.3. Figures
II-4, II-5). However, no quantitative data can
be obtained as to the production distribution
among the two processes because such information
would be proprietary. Yet, there are very signi-
ficant differences in the waste streams produced
by each process.
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To complicate matters further, a new variant
of these processes, the particle form process (Sec-
tion 3.2.1.3.3., Figure II-6) has recently been
introduced. From the standpoint of waste streams,
the most important aspect of this latter process is
that there is no catalyst removal step. In the
Ziegler process, an aqueous catalyst removal step
is involved which eventually produces aluminum and
titanium oxides. In the Phillips process, the cat-
alyst is separated as a finely divided solid con-
sisting of a ceramic-type mixture of alumina and
chromium oxides. Because of the ceramic nature of
the catalyst, there is no chromium leachate.
In addition to these streams, there are off-
grade products and, in the Ziegler process, bottoms
from aqueous alcohol recovery. This latter stream
goes to the wastewater treatment facilities where
it contributes to the production of biological sludges.
4.1.6 SBR Rubber
Two methods are used in the production of SBR
rubber: The solution polymerization process and
the emulsion polymerization process.
If the solution process is used, the washed
butadiene stream has to be dried in an absorbent
The adsorbent can be regenerated over many cycles;
but it must eventually be discarded, and it thereby
creates a waste stream. When Ziegler type catalysts
are used in the solution process (Section 3.2.1.3.,
Figure II-5) , the typical alumina and titanium dioxide
sludges are also produced, constituting another source
of wastes.
In the emulsion process (Section 3.2.1.1., Figure
II-2) wastewater treatment sludges constitute another
waste'stream. A waste stream, at certain locations,
consists of the alkaline wash used to remove catechol,
which stabilizes the butadiene stream. Both emulsion
and solution processes contribute to this type of
waste stream.
Additional waste streams may be generated where
master batching constitutes a significant proportion
of the production. These include:
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Carbon black dusts (sometimes in the form
of a wet scrubber sludge.)
Waste additive oils resulting from spillages
or production upsets. These are often caught
in special traps or pits.
Storage tanks and equipment cleanings also con-
tribute to waste streams, as do off-grade products.
4.1.7 Polyvinyls
Polyvinyl chloride and polyvinyl acetate are the
main products in this group. Polyvinyl chloride is
produced in greater quantity. The two main processes
that are used are suspension or emulsion polymerization
and bulk polymerization.
Waste streams generated in suspension or emulsion
polymerization of polyvinyl chloride include:
Off-grade finished product, which can be as
high as 2.0% of total production.
Wastewater sludges, amounting to 11 Kg/KKg
of production (1.1%) and possibly in-
cluding vinyl chloride monomer from reaction
cleanings
Fines from polymer separation
Sweepings, which can include dusts (although
with current OSHA requirements, dust produc-
tion should be reduced)
Scrap pellets.
Waste streams constituted in polyvinyl acetate
production include off-grade products (discolored
resin chunks), which are estimated to be 10 Kq/KKq
of production. In addition waste streams may be
generated by:
Still bottoms containing olisomers and vinyl
chloride dissolved in vinyl acetate
Filtered latex waste when polyvinyl acetate
is processed as the latex
Vinyl acetate copolymer.
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4.1.8 Polypropylene
Polypropylene is produced by a variety of process
variations quite similar to those used for high density
polyethylene (Section 3.2.1.3.2, Figure II-5). The
general waste streams associated with polypropylene
and high density polyethylene are similar. However,
as with high density polyethylene, the variability
contributes to the difficulty in quantifying the
waste streams.
Off-grade products are estimated to account for
0.5% of total production. Still bottoms and waste
oils may account for 10 Kg/KKg of production, thus
constituting another source of waste. Amorphorous
polypropylene may, under adverse economic conditions,
constitute a portion of the still bottoms. However,
this material can be used for certain applications,
e.g., adhesives.
In those plants using variations of the Ziegler
process, an aluminum hydroxide waste stream is generated,
Newer variations (particle form process, Section
3.2.1.3.3., Figure II-6) utilize more efficient cat-
alysts that can be left and incorporated into the
finished product. Other sources of waste streams
include:
Fines water streams and dust collectors
Wastewater treatment sludges
Aqueous wastes with polymer solids
Scrap flakes.
4.1.9 Other Synthetic Rubbers
The waste streams encountered in production of
such rubbers as neoprene, EPM, EPDM and polybutadiene
are similar to those encountered in SBR production
(Section 3.2.1.1., Figure II-2). These would include:
Wastewater treatment sludges
Scrap
Fines in sludge water
Fines from dust collectors.
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In addition, spent adsorbent and spent catalyst
constitute a waste stream with these other synthetic
rubbers. At one location, vanadium waste stream is
produced from the used catalyst; however, the metal
is reduced to 1 ppm when diluted in other plant waste-
waters. The still bottom and waste oil streams are
estimated to be 60 Kg/KKg of production of neoprene.
4.1.10 Phenolic Resins
The phenolic resins (Section 3.2.3.1.1., Figure
11-11) present waste streams which deserve consider-
able attention. Water is generated during the reaction
and is distilled off from the reactors. There is en-
trainment of oligomers, unreacted phenols, and other
organic components in this very significant water
stream. This source of waste is estimated (on a wet
basis) to be about 500 Kg/KKg of product produced
with an organic content of 5% to 15%. These wastes
also contain large amounts of phenols, substituted
phenols and cresols in addition to other organic
components. As previously mentioned in Section 3.2.3.1.,
no satisfactory method of handling this waste stream
has been devised. These wastes are essentially hazardous
and are discussed in Section 4.3.
Other significant waste stream sources are com-
posed of off-grade product (which is estimated to be
8 Kg/KKg of product produced) and wastewater
sludge which is estimated to be 60 Kg/KKg and which
may contain partially unreacted product.
4.1.11 Amino Resins
The process flow diagram for amino resins was
previously presented in section 3.2.3.2. Figure
11-12). Waste stream identification includes:
Off-grade material constituting an estimated
10 Kg/KKG of product produced
A significant proportion of production in
still bottoms and waste oils (42 Kg/KKg)
Filter cake from the production of liquid
resins.
In addition, wastes are generated from bad pro-
duction batches, usually caused by unreacted formalde-
hyde. One solvent (methanol) may also be part of wastes
produced, depending upon the efficiency of the system.
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4.1.12 Coumarone-Indene
These resins (Section 3.2.3.3, Figure 11-13
are almost insignificant in terms of production
volumes as compared to the large volume of poly-
ethylenes in vinyl chlorides. They are practically
free of waste streams. The petroleum distillates
may be utilized as boiler fuel. Still bottoms
(lower-grade material) are sold at a discount.
The major waste stream consists of spent
clay (36 Kg/KKg of production). This results
from those processes that use boron trifluoride as a
catalyst during the polymerization step. Attapulgite
clay and lime are used to remove boron/fluorine and
spent catalyst. The resulting spent mixture is
filtered out and consists of about 60% clay/calcium
hydroxide and 40% organic residue. The boron
trifluoride or its decomposition products are likely
to be in this waste stream.
4.1.13 Alkyd Resins
The products containing alkyd resins are
extremely numerous and vary greatly. Therefore,
generalizations based on the necessarily limited
field investigations are of limited validity. Sec-
tion 3.2.3.5 previously described general produc-
tion (Figure 11-15).
Wastes usually associated with alkyd resin
production include:
Off-grade product (1 Kg/KKg of produc-
tion)
Sweepings from warehouse wastes.
Bulk shipping of monomers in a production
facility is the exception rather than the rule.
Therefore, when solid, these monomers contribute
significantly to the composition of warehouse
wastes and represent a measurable fraction (0.1
Kq/KKg of production) of the production volume.
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4.1.14 Epoxv Resins
These resins (Section 3.2.3.4, Figure 11-14)
are condensation products of epichlorohydrin,
bisphenol A and other co-monomers. The observa-
tions made for the alkyds (in Section 4.1.13)
apply equally well to this group of products.
The identifiable, but highly variable waste
streams, could not be quantified but include:
Off-grade products
Off-grade raw materials
Still bottoms
Waste solvents (xylene).
4.1.15 Polyurethanes
The bulk of the production (described in
Section 3.2.3.6, Figure 16) is performed at the
manufacturing site where end-use products are
made. Prepolymers are centrally manufactured in
some plants in equipment which is sometimes even
used for the manufacture of other groups of products,
e.g., alkyds or epoxy. This equipment consists of
batch reactors equipped with condensers which can
work either as reflux or distillation condensers. The
waste streams consist of washings, filter cakes,
oligomers and solvents.
4.1.16 Silicone j»
As previously discussed in production pro-
cessing of silicones (Section 3.2.3.7, Figure 11-17),
specific quantification of waste streams in silicone
production is difficult. The waste streams include
off-grade products which constitute an estimated 54
Kc/KKg of production. Still bottoms and raw material
waste oils are estimated at a 58 Kg/KKg of production.
Other estimated wastes include spent adsorbent and
scrap (33 Kg/KKg of production).
Additional sources of waste stream generation
include:
Waste solvent from silicone resin production
Filter cake used in a filtering step of
silicone resin production.
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4.1.17 Cellulosic
The waste streams from the viscose rayon
process are essentially aqueous solutions, semi-
solids (hemicellulose), fine slurries and
sludges (Section 3.2.4.1, Figure 11-18).
In the production of acetate and triacetates
(Section 3.2.4.2, Figure 11-19), the waste streams
also include recovered acetic acid streams, which
are usually reused in process or recovered for other
purposes. Heavy concentrations of magnesium sulfate
salts are also encountered. Cellulosic sludges
are also produced.
4.2 Waste Stream Characterization In Spinning Operations
The spinning processes produce essentially three
types of wastes (Figure 11-20) :
Various types of off-grade products at
various stages of manufacture
Sludges from the treatment of waste baths
Still bottoms from solvent recovery.
In the following paragraphs, the specific nature
of the waste streams associated with the various fibers
and the various spinning methods are discussed in more
detail. As usual, the discussion follows the order of
decreasing importance in terms of weight processed.
4.2.1 Polyester Spinning Wastes
Because these products are generally spun from
the molten state and because the material which
has to be discarded for one reason or another
can either be remelted or depolymerized, off-grade
product wastes are insignificant. The waste
sand, where sand filtration is used ahead of the
spinneret, constitutes an insignificant stream.
A stream of waste finishes exists in some
operations. This stream has been reported as
being recovered in oil traps at a wastewater
treatment facility.
Finally, a stream of triethylene glycol is
sometimes produced from cleaning operations. It
can usually be recovered.
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4.2.2 Nylon Spinning
Nylon is spun from the molten state. The only
waste streams from the spinning and finishing opera-
tions are said to be irrecoverable waste fiber and
yarn, biodegradable and non-biodegradable finishing
oils. In addition, a small stream of lubricant
from various pieces of equipment is encountered
in some installations.
4.2.3 Acrylic And Modacrylic Spinning
From the standpoint of waste generation, at
least three widely different methods of spinning
acrylics have been reported. Two methods are
variants of the wet spinning process and one is
a dry spinning method. The significant factor
in the wet spinning process is the type of solvent
used to form the dope. In certain instances, the
acrylic material is dissolved in high concentrations
of metal salts in water. In another variant, a
water miscible solvent is used. Obviously, the
wastes are quite different, depending on what
process is used.
Large amounts of sludges containing metal ions
have been acknowledged at several locations. A
frequently mentioned ion has been zinc. On the other
hand, some other installations (or some lines in
the same plant) use different processes, e.g., dry
spinning. In this case, a volatile solvent is
used rather than a metal salt solution, still
bottoms may be obtained and also biological sludges,
if there is a biological treatment. It is diffi-
cult, therefore, to generalize the waste streams
since distribution of the production across the
three methods is not known. The dry spinning
method is used for some modacrylics and is said
not to produce any significant waste other than
off-grade material.
4.2.4 Acetate And Triacetate Spinning
The spinning of acetate and triacetate fiber
involves the dry spinning methods and exhibits
the characteristic waste streams of this method.
The main waste stream is off-grade material which
can be hydrolyzed and returned to process.
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4.2.5 Rayon Spinning
The spinning of rayon involves complex baths
which have to be periodically readjusted or cleaned.
Considerable wastewater containing high concentra-
tions of all kinds of salts, organic and mineral
compounds is generated. Extensive wastewater
treatment is required with production of large
amounts of sludges, which may contain leachable
metallic ions.
In addition, warehouse dusts and sweepings
may be generated in the handling of chemicals
constituting the baths or added to the dope
formulation. The use of such materials as dia-
mines and dithiocarbamates has been reported.
Large amounts of zinc salts are also reported to
be used.
4. 3 Potentially Hazardous Waste Streams And The Criteria
For Their Classification
This section addresses streams which are designated
as potentially hazardous when rated against the criteria
of toxicity, flammability, etc. The streams identified
as potentially hazardous include:
SIC 2821 — Plastic Resins
Wastes from phenolic resin production
Amino resin waste streams
Antimony and manganese catalyst waste
from polyester production(D
Still bottoms from solvent or monomer
recovery in:
ABS-SAN resins
Polystyrene
Polypropylene
Silicone
Warehouse dusts from alkyd production
Polyester waste streak is listed under SIC 2821 to reflect
the fill that the stream is generated at the polymerization
step. It is understood that a considerable amount of
polyester production occurs in SIC 2824.
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SIC 2822 - Synthetic Rubber
Still bottoms from solvent or monomer
recovery in
SBR via the solution process
Polybutadiene rubber
Neoprene rubber
SIC 2823 — Cellulosic Manmade Fibers
Diamine and dithiocarbamate dusts and
powders from rayon production
Wastewater treatment sludges from
rayon production
SIC 2824 — Non-Cellulosic Manmade Fibers
Zinc containing sludges from the
spinning of acrylics and modacrylics.
By and large, company personnel in the plants visited
are acutely aware of the potentially hazardous nature of
the streams identified by the study team.
4.3.1 Criteria For The Classification Of Waste
Streams As Potentially Hazardous In The
Plastic Materials And Synthetics Industry
A potentially hazardous waste stream refers to
any waste or combination of wastes which pose a sub-
stantial present or potential hazard to human health
or living organisms because such wastes are suspected
of being:
Toxic (including carcinogenic)
Flammable or explosive
Corrosive or reactive
Biologically magnified or persistent.
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These types of hazards represent four out of five
basic hazardous characteristics of wastes which
were established in EPA's report to Congress,
Disposal of Hazardous Wastes. The fifth character-
istic, radioactivity, does not apply to the wastes
generated by SIC 282.
According to the mandate given to Foster D.
Snell, Inc., by EPA, detailed original toxicological,
chemical and biological investigations to determine
the potential for hazard creation bv the literallv
thousands of substances in these industries which
may become wastes was not a requirement. Instead,
reliance on published sources which are compendia
of much of the required information was the preferred
approach. The sources chosen were:
Reference 1 — Dangerous Properties of
Industrial Materials (4th Ed.) N. Irving
Sax (New York: Van Nostrand Reinhold
Company, 1974).
Reference 2 — Clinical Toxicology of
Commercial Products (3rd Ed.) Gleason,
Gosselin, Hodge and Smith (Baltimore:
The Williams & Wilkins Co., 1969).
Reference 3 — A Study of Hazardous Waste
Materials, Hazardous Effects and Disposal
Methods, Booz, Allen Applied Research, Inc. ,
United States Environmental Protection
Agency (Contract #68-03-0032)(Cincinnati,
Ohio: 1972) .
For the purposes of this study, oral toxicity was
accepted as the basis for defining a toxic substance
because more data are generally available to support
published conclusions based on this parameter.
Hazardous rating scales from these publications are
presented in Appendix A, Methodology. Information
from these sources were supplemented by the companies
interviewed and judgments of the study team. Chemical
analysis of spot samples of wastes obtained from
industry sources aided in the quantification and
substantiation of some of the streams classified as
potentially hazardous.
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During the course of the study, the following
hazardous constituents were found to be in the wastes:
Phenols
Antimony, zinc and manganese ions
Aromatic and chlorinated hydrocarbons
Diamines and dithiocarbamate dusts
Maleic anhydrides.
The discussion below briefly presents information on
why these substances are considered to be hazardous.
The next section, 4.3.2, relates the substances
identified to specific waste streams generated by
this industry.
4.3.1.1 Phenols
Phenols have been assigned (1,2,3) a high
hazard rating. That is, death or permanent injury
may occur after very short exposure to small quan-
tities. In acute phenol poisoning, the main effect
is on the central nervous system; chronic poisoning,
following prolonged exposures to low concentrations
of the vapor or mists, results in digestive dis-
turbance (vomiting, difficulty in swallowing, exten-
sive salivation, diarrhea, loss of appetite), nervous
disorders and skin irritations. Chronic poisoning
may terminate fatally in cases with extensive damage
to the kidneys or liver. Phenols have been assigned
a moderate hazard rating(3) for flame, explosion
and reaction in soil.
(1) Dangerous Properties of Industrial Materials (4th Ed.) N. Irving
Sax (New York: Van Nostrand Reinhold Company, 1974).
(2) Clinical Toxicology of Commercial Products (3rd Ed.) Gleason,
Gosselin, Hodge and Smith (Baltimore: The Williams & Wilkins
Co., 1969).
(3) A Study of Hazardous Waste Materials, Hazardous Effects and
Disposal Methods, Booz Allen Applied Research, Inc., United
States Environmental Protection Agency (Contract #68-03-0032)
(Cincinnati, Ohio: 1972).
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4.3.1.2 Antimony Zinc And Manganese Ions
Antimony compounds have been assigned highly(^
and extremely (2> toxic ratings. In humans, com-
plaints referable to the nervous system have been
reported. Animals exposed to fumes of antimony
oxide have developed such symptoms as pneumonitis,
fatty degeneration of the liver, polymorphonuclears
and damage to the heart muscles.
Zinc salts have been assigned^) a toxicity
rating of very toxic. Toxicity and toxic actions
are like those of copper salts. They produce irri-
tation or corrosion of the alimentary tract with
pain, emisis, etc. Zinc exhibits its greatest
toxicity towards fish and aquatic organisms. In
soft water, concentrations of zinc ranging from
0.1 to 1.0 mg/liter have been reported to be lethal.
The toxicity of zinc salts is increased at lower
concentrations of dissolved oxygen in about the
same proportion as for lead, copper and phenols,
e.g., the lethal concentration at 60% saturation
of dissolved oxygen is only about 0.85 that at
100% saturation.
Manganese salts are regarded^) as being
moderately toxic to humans. As with industrial
exposure to dust, nervous symptoms predominate.
In ground water subject to reducing conditions^)
manganese can be leached from the soil and occur
in high concentrations. Many organisms are capable
of concentrating manganese in their bodies to many
times above the concentration in sea water.
4.3.1.3 Aromatic And Chlorinated Hydrocarbons
Aromatic hydrocarbons are regarded^) to be
very toxic and in many cases quite flammable. These
materials are toxic by all portals of entry. Some
aromatic hydrocarbons are suspected of being carcino-
genic agents. Chlorinated hydrocarbons are under
suspicion of being carcinogenic. Chlorinated solvents
are liver and kidney poisons and central nervous
depressants(2).
(1) Dangerous Properties of Industrial Materials (4th Ed.) N. Irving
Sax (New York: Van Nostrand Reinhold Company, 1974).
(2) Clinical Toxicology of Commercial Products (3rd Ed.) Gleason,
Gosselin, Hodge and Smith (Baltimore: The Williams & Wilkins
Co., 1969).
(3) A Study of Hazardous Waste Materials, Hazardous Effects and
Disposal Methods, Booz, Allen Applied Research, Inc., United
States Environmental Protection Agency (Contract #68-03-0032)
(Cincinnati, Ohio: 1972).
(4) Water Quality Criteria,, McKee, Y.E., H.W. Wolf, Eds., Resources
Agency of California State Water Quality Control Board.
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4.3.1.4 Diamines And Dithiocarbamates
Phenylenediamine, for example, is regarded d)
as being very toxic. Indeed, it is a suspected
cause of bladder tumors in "aniline" workers.
Dithiocarbamates are also regarded as being
very toxic. Zinc dibutyldithiocarbamate is a
recognized(2) carcinogen. The diethyl and dimethyl
analogues are recognized (^) e.s being carcinogenic,
as well.
4.3.1.5 Maleic Anhydrides
Maleic anhydride, when reacted with water, will
produce heat. When heated, it will emit toxic fumes.
In addition, its acute local and systemic effects
are rated high for humans.
4.3.2 Potentially Hazardous Waste Streams
The following discussion presents those waste streams
which are potentially hazardous and the rationale behind
their classification, case by case.
Foster D. Snell,Inc.,analyzed waste samples obtained
from industry sources to spot check the assumptions made
as to components and concentrations constituting the
wastes. The results of the analytical program and the
methodology employed in the analysis of wastes are pre-
sented in Appendix B.
4.3.2.1 Wastes From Phenolic Production
The wastes from phenolic production present
themselves in the form of: solutions containing a
large amount of water with variable concentrations
(5% to 15%) of the organic materials, specifically
phenols and discarded off-grade, partly unreacted
products also containing excess phenols. This waste
stream has high toxicity because phenol compounds
are present.
4.3.2.2 Wastes In Amino Resins
In at least one instance, the disposal of partly
unreacted amino resins has been mentioned. This
stream is fortuitous in nature, resulting from equip-
ment breakdown or human error. However, its occurrence
over a period of time cannot be discounted.
(D Clinical Toxicology of Commercial Products (3rd Ed ) Gleason,
Gosselin, Hodge and Smith (Baltimore: The Williams S, Wilkins
Co., 1969).
(2) Dangerous Properties of Industrial Materials (4th Ed.) N. Irving
Sax (New York: Van Nostrand Reinhold Company, 1974).
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The toxicity of the streams results from excess
unreacted formaldehyde. In addition, an overhead
stream of formaldehyde contaminated methanol is
produced. This stream is considered hazardous
because of the toxicity of formaldehyde combined
with the high flammability of the mixture.
4.3.2.3 Antimony And Manganese Catalysts In
Polyester
The literature indicates the use of acetates of
cadmium, cobalt and manganese in polyester production.
In addition, the antimony-containing catalyst has
also been mentioned in the industry interviews. A
stream of waste catalysts (as distinct from a potential
catalyst sludge, which was not mentioned in any
interview) originates from the very dust control
equipment installed to protect the workers handling
this material. The toxicity of this stream results
from the chemical species — antimony, manganese or
cadmium.
4.3.2.4 Still Bottoms
Still bottoms are those fractions obtained from
rectification columns used to purify or separate
solvents. There are two types of still bottoms:
aqueous and non-aqueous.
As a rule, the aqueous still bottoms are handled
in wastewater treatment facilities where they do not
present any particular problem. Sometimes these
aqueous still bottoms may contain immiscible oils
which are separated at the treatment facilities.
The non-aqueous still bottoms may be potentially
ha2ardous by reason of their flammability. In
addition, they may be considered suspect if they
contain significant amounts of polycyclic aromatics.
For these reasons, it would appear that the still
bottoms generated in the manufacture of the products
listed below are potentially hazardous:
ABS-SAN
Polystyrene
Polypropylene
SBR (solution process)
Polybutadiene
Neoprene.
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4.3.2.5 Waste Solvents In Silicone Resin
Production
The production of silicone resin is carried
out in only five plants in the United States. The
technology is perhaps the most proprietary of those
encountered in the whole industry (with the possible
exception of spinning).
Improper disclosure of confidential information
may result from detailed discussion of this item.
Special disposal of these solvents has been reported
which, by implication, classifies them as potentially
hazardous wastes.
4.3.2.6 Hazardous Wastes In Rayon Production
Recently, production of rayon in the United
States has declined considerably. Economic con-
siderations have been always mentioned for the closure
of production facilities. Nevertheless, another
potential cause of this trend may have been the
impossibility of meeting effluent guidelines for
wastewater. Thus, the classification of some of the
streams from the rayon process as potentially hazar-
dous may be academic. Two areas of potentially
hazardous waste include:
Dusts or spills from the handling of
dithiocarbamates and ethylene diamine,
which have been mentioned as additives
Highly metal contaminated wastewater
treatment sludges.
Considerable amounts of zinc have been reported
in the wastewaters. This, in turn, would be pre-
cipitated as zinc oxide in the sludge. Zinc oxide
is highly leachable and, thus, the sludges are
potentially hazardous. An amount of 25-50 Kg/KKg
of product (dry weight) has been reported for rayon
production sludges.
4.3.2.7 Hazardous Wastes In Acrylic And
Modacrylic Production
In this production, a considerable amount of
zinc-bearing wastewater sludges has been reported.
11-144
-------
4.4 Waste Quantification For The Years 1974, 1977 And 1983
(Plastic Materials And Synthetics Industry)
In this portion of the report, estimated total and
potentially hazardous waste quantities for the industry are
presented for the year 1974, and projections are made for
1977 and 1983. The data is based on the results of industry
interviews, literature search, the analytical procedures
carried out on actual waste samples obtained from industry
sources and the INFORUM input/output model.
The required information is presented in a series of
tables:
Table 11-40 — Estimated 1974 Geographic
Distribution Of Wastes For The Major Poly-
merization Operations
Table 11-41 — Estimated 1974 Geographic
Distribution Of Wastes For The Spinning
Operations
Table 11-42 — Total Estimated Wastes For
The Years 1974, 1977 And 1983.
The following paragraphs discuss the rationale used in develop-
ing these tables.
4.4.1 Total Wastes
Total wastes for the industry in 1974 were developed
by multiplying the sum of the waste factors for each
of the products manufactured (found in Tables 11-37 and
11-39) by the production values for these products.
Table 11-40, provides the total wastes by
product for 1974 for polymerization operations.
Table 11-41, does the same for spinning operations.
The values presented in Tables 11-40 and 11-41 were added
together to obtain the 1974 values presented in Table
11-42, which summarizes the wastes for SIC 282 as an
aggregate.
11-145
-------
TABLE II-40(1)
ESTIMATED 1974 GEOGRAPHIC DISTRIBUTION OF
WASTES FOR THE MAJOR POLYMERIZATION
OPERATIONS OP THE PLASTIC MATERIALS AND
SYNTHETICS INDUSTRY—SIC 282 (6)
(WET BASIS) (KKg/YEAR)
POLVBSTBRS
POLYAMIDES">
Potentially'D
Toul Hazardous
Wastes WaatS*
Potentially (3>
Total Hazardous
Wast** WastM
IV
X
IX
VI
DC
vin
i
DI
IV
IV
K
X
V
V
VII
vn
rv
VI
i
m
i
V
V
IV
vn
vm
VII
IX
i
ii
VI
D
IV
vm
V
VI
X
m
i
rv
VID
IV
VI
vm
i
m
X
m
V
vrn
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyomine
(D)
2.44:
ID)
(D)
1.SS1
124
CD)
fD)
(D)
1.023
744
775
24S
32.468
(D)
(D)
31
120
21.450
23.170
465
(D)
(D)
0»
fD)
N.A.
0»
MS
t cat
11-146
-------
TABLE II- 40 (2)
POLYKTHYLENES
HIGH DENSITY
LOW DENSITY
IV
X
IX
VI
K
vin
i
in
rv
IV
DC
X
V
V
VII
vn
rv
VI
i
A! abama
A 1 as k .1
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Potentially
Total Hazardous Total
Wastes Wastes! 1) Nutec
(D)
(D)
(D)
(D) (D)
(D) 5. 401
Potentially
Hazardous
Wastes! 1)
Maryland
I
V
V
rv
vn
vin
VII
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
I
II
VI
n
iv
vin
v
VI
X
ni
i
iv
vin
iv
VI
vm
i
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Isiand
South Carolina
South Dakota
Tennessee
Texas
6,755
8.0*0
Utah
Vermont
Virginia
x
HI
y
vin
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
9.058
28.964
Region
ni
IV
J&L
VI 6,755*
VD fD)
JSL.
vni
JBJ_
(D) • WUfcfoKS to tieSt dncta*ng figure! tor indiitduil conpaoici.
fl) No >ottnU«Uy Sunrtooi vutei
Taaci O. Purr. IDC. conpiunora tnt uutlym of *«J= m*na Kforxt during the Indue? mrvty.
11-147
-------
TABLE n-40 (3)
rv
IX
VI
rx
VID
I
ni
rv
rv
rx
X
v
v
VII
VII
rv
VI
i
m
v
v
rv
vn
VIII
VII
IX
i
ii
VI
n
rv
vin
v
VI
X
III
1
rv
VID
rv
VI
vrn
i
m
X
ni
v
vm
POLYVPfYL CHLORIDE
Potanttally
Total Hazardous
W.itBC Wamte.m
Alabama
Alask.i
Arizona
Arkansas
California tt»)
Colorado
Connccticui
Delaware (D)
Florida (D)
Georgia
Hawaii
Idaho
Illinois (D)
Indiana
Iowa
Kansas
Kentucky (D)
Louisiana 8.215
Maine
Maryland (D)
Massachusetts 5.580
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey 6.913
New Mexico
New York (D)
North Carolina
North Dakota
Ohio 8.060
Oklahoma (D)
Oregon
Pennsylvania CD)
Rhode Island (D)
South Carolina
South Dakota
Tennessee
Texas i.765
Utah
Vermont
Virginia
Washington
WestVireinia 3.317
Wisconsin
Wvomine
TOTAL 68,572
Region I 5,580+
H 6,913+
HI 3.317+
rv tD)
V 8.060+
POLYPROPYLENE
Potentially Flammable
Total Baiardou* Aliphatic
•..i.. Waat*. SOU Bottom*
(D) (D) 0»
(D) (D) (D)
(D) CD) n»
8.399 4.940 4.940
(D) (D) (D)
17.442 10.260 10.260
CD) (D) (D)
(D) (D> P)
8.398+ 4.940+ 4.940+
V117.980+
vn
vni
rx (Di
X
Note*
(t>) > wlihtetd to tvoid dUcloang Tigum for individual compcniei.
(1) *4o^ctcimally lu»«idoui wasici
Source Foster IX Sncll, Inc. compilaoons *nd inilyus of waite Rieami rcponed dunng the indunry
11-148
-------
TABLE II- 40(4)
IV
X
IX
VI
DC
VID
I
III
IV
rv
IX
X
v
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticu!
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
ABS-SAN
Potentially Aromatic
Total Hazardous Still
Wastes Wastes Bottoms
(D) (D) (D)
(D) (D) (D)
POLYSTYRENE
Potentially
Total Hazardous
Wastes Wastes
3.600 3.000
(D) (D)
4.116 3,430
Aromatic
Still
Betlfims
3.000
(D)
3.430
Indiana
Vll
Vll
IV
VI
I
ni
i
v
Iowa
Kansas
Louisiana
JSi.
Maine
Maryland
Me
5achi
JBL
4.512 3.760 3,760
IV
vn
VI
IV
Michigan
Mississippi
Mi
New Hampshire
New- Jersey
(P)
_ffiL
New Mexico
Ne
York
North Carolina
Da
(Dl . (D] 1SL
(Pi _ (PI
III
Ohio
(D)
5.488 4,540
Pennsylvania
VIII Utah
I
ra
ni
Vermont
JBL
TOTAL
15,840 2.200
2,200 22.128 18.440 18.440
3,760-
11-149
-------
TABLE D- 40(5)
Total
Wastes
ACRYLICS
Potentially
Hanrdous Total
Wastes (1) Wastes
SBR
Potentially
Hazardous
Wastes (2)
Arena tic
Still
Bottoms
IV Alabama
X
DC
VI
DC
vin
i
ni
IV
rv
DC
X
V
V
vn
VII
rv
VI
!
m
i
V
V
rv
vn
VIII
VII
DC
i
ii
VI
n
rv
vin
V
VI
X
m
i
rv
VID
rv
VI
vm
i
m
X
m
V
vm
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kan EBB
Kentucky (D)
Louisiana (D)
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas l.»80
Utah
Vermont
Virginia
Washington
West Virginia CD)
Wisconsin
Wyoming
TOTAL 2.709
Region I
' n
HI (D)
rv (D)
V
VI 1.880*
vn
(D)
1.050
CD)
CD)
CD)
CD)
11.163
(D)
fD)
CD)
CD)
8.175
fD)
CD)
23.250
52.910
1.050*
(D)
(D)
CD)
8,175*
84.413
(D)
252
CD)
CD)
CD)
CD)
_. *.«.7»
. (P)
(D)
(Dl
roi
2.202
mi
CD)
5. 580
CD)
252
CD)
(D)
CD)
(D)
2.679
CD)
CD)
(D)
ID]
2.202
mi
(D)
5.580
12.6S8 12.696
252*
CD)
(D)
CD)
2.202*
8.259
252*
(D)
fD)
fD)
2.202*
1.259
vni
DC
(D)
(D)
(Dl
X
fD) . withheld 10 I»oid dtKlo^ng Ufatt far tadlvUii*! cooyuiu.
(1) No fcienitlly huudoui VMU
ft) Vtlne Jor «1I ovm b tbe iKagc far two pnnlucBon piiic.ari - BlutlaD Md «mu»<»
SMICT Fomr U SneU. Inc. conpUmlioM «nd «o«lxi« «' »«• «»«nu Kponul d«Hi« tte laduBJy Hmy
11-150
-------
TABLE U- 40 (6)
PHENOLICS POLYBUTADIENE
IV
X
IX
VI
re
V1D
I
DI
IV
IV
DC
X
V
V
VII
VII
IV
VI
I
ni
i
V
V
IV
VII
VHi
VII
IX
1
II
VI
n
IV
vin
v
VI
X
III
I _
IV
VHI
VI
V
Total
Wastes
Alabama (D)
AldSk.l
A r i z on a
Arkansas
California 34.800
Colorado
Connecticut (D)
Delaware
Florida (D)
Georgia
Hawaii
Idaho
Illinois (D)
Indiana
Iowa
Kansas (D)
Kentucky
Louisiana
Maine
Maryland
Massachusetts (DJ
Michigan (D)
Minnesota
Mississippi
Missouri
Montana (D)
Nebraska
Nevada
New Hampshire
New Jersey 31,800
New Mexico
New York 64,800
North Carolina 8.600
North Dakota
Ohio 74.400
Oklahoma
Oregon 24.000
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas 31.200
Utah
Vermont
Virginia
Washington [PJ . .
Wisconsin (D)
TOTAL 366,000
Region 1 (D)
II 96.600
ni
IV 8 . 600*
V 74.400*
vn (D)
DC 34.800
X 24.000*
Aqueous
Potentially Solution Of Potentially Aliphatic
Hazardous Phenol And Total Hazardous Still
Wastes Formaldehyde Wastes Wastes Bottoms
(D) (D)
34,800 34.800
(D) (D)
(D! (D)
(D) (D) CD) (D) (D)
(D) (D)
(D) (D) (D)
(D) (D)
CD) CD)
CD) (D)
31.800 31.800
64.800 64.800
8.600 8.600
74.400 74.400
31.200 31 200 BE9 M ifi .
'D' CCU •
366.000 366,000 1,049 48 «B
(D) (D)
96.600 96.000
8,600* 8.600* CD) CD) CD)
74 400* 74,400* CD) CD) (D)
-in onTi Ti 200 869 40 ^0
CD) (P) _ _ _
34.800 34.800 .
24.400* 24.400* — _ _ —
« D. Sncll. me. ccn,pil«o« .no analyse of w«tt «•""» '
red dunig «hc .
11-151
-------
TABLE n- 40 (7)
AMINO RESINS
ALKYDS
rv
X
rx
vi
rx
vin
i
m
rv
rv
rx
X
v
v
VII
vn
rv
VI
i
m
i
v
v
rv
vn
vm
VII
IX
i
ii
VI
n
rv
vin
v
VI
X
in
i
rv
VID
rv
VI
vm
i
ID
X
ni
v
vin
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
TOTAL
Region I
n
ni
rv
V
VI
vn
vni
rx
X
I
I
(D)
CD)
(PI
1.265 1
CD)
CD)
CD)
(D)
MS
(D)
(D)
(D)
CD)
2,310
•60"
1.815
1.540
1,540
1.430
BBO
MO
(P)
1.045
385
770-
1.045
20.735
1.155*
m M*II
1.815*
3.245*
4.235
1.045*
(PI
1.705*
770
Ily Haiardout Waitei
I/Formaldehyde Mix
! 1
(D) (D)
CD) (D)
CD) CD)
(D) CD)
..265 166
CD) CD)
(D) CD)
(D) (D)
(D) (D)
_225 210
(D) CD) _
CD) CD) .
(D) (D)
(D) CD)
2.310 764
(60 504
1.815 386
640 1.176
1.540 1,176
1.430 1.092 _
BBO 672
MO 504
(D) CD)
1.045 798.-
385 294 _
770 588 _
1.045 798
20.735 15.834
1.155* 882*
1.B15* 1.386*
3.245* 2.478+
4.235 3.234
1.045+ 798+
(PI CD)
(PI (Dl
1,705* 1.S02+
770 5B».
ehyde Contaminated
roducti
S •
E *
5 •
£ *
70
CD)
CD)
(D)
(D)
70
230
CD)
(D)
(D)
CD)
SO
7U
CD)
CD)
(D)
CD)
420
120
330
~~2S6
280
260
160
(D)
190
70
1*0 -
190
3.770
210*
330*
590*
770
190*
(D)
(Dl —
S10+
1*JU
aatea
illy Haiardoui Waste
fl I
1 s.
CD) (D)
~~S7 5
CD) CD)
CD) (D)
8 1
6 1
44 4
B 1
(Dl CD)
10 1
10 1
10 1
1
(D) CD)
13 1
51 5
18 2
—21 5
CD) (D)
25 2
(D) CD)
(D) CD)
19 2
(D) CD)
6 1
349 32
10 1
69 7
35* 3*
24+ 3+
95+ 9+
19 2
13+ 1 +
57 5
ind Phthallc Anhydr
Inated Floor Sweepln
Z.u
(D)
CD)
(D)
1
1
4
1
CD)
1
1
1
1
(P)
1
5
5
2
(D)
2
(D)
(D)
2
CD)
i
32
1
3+
3+
8+
2
1*
(D)
(5)
(D) * Wltfataeld to avoid due losing figuitt for individual compaiuci.
Source Foner D. Sncll, Inc. compilations and analysis of wane nicami rcportcO dunng the lodim^ survey.
11-152
-------
TABLE H-40 (8)
NBOPRENE
•UTYL RUBBER
IV
X
IX
VI
IX
VIII
1
11]
rv
IV
IX
X
V
V
VII
VII
IV
VI
!
ni
i
V
V
IV
VII
VIII
VII
IX
I
n
VI
II
rv
VIII
V
VI
X
Til
1
TV
VID
a'
VI
VIII
1
III
x
III
y
VID
Hotel
rt>) •
(1) r
HI M
Flammable
Chlorinated
Potentially Hydrocarbons
Total Hmardous And Aromatic Total
Wastes Wastes Still Bottoms (1 ) Wastes
*:
-------
KPM-BPDM
TABLE 0*40 (9)
COUMAHONE -PTOENE
IV
X
DC
VI
DC
vin
1
ni
IV
IV
DC
X
V
V
vn
vn
IV
VI
i
m
i
V
V
IV
vn
vm
VIJ
DC
i
u
VI
n
IV
vm
V
VI
X
m
i
IV
vin
IV
VI
vin
i
m
X
m
V
vm
Total
Wastes
Alabama
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana (D)
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas (D)
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
Potentially Potentially
Haiardous Total Hazardous
Wastes(l) Wastes Wastes
(D) (D)
(D) CD)
(D) (D)
CD) 0»
(D) (D)
(Dl , (D)
L
CD) CD)
1.116 1.116
ID1 mi
mi mi
TOTAL
33
5,321
5.321
Region
1.116*
(1) No potentially haurdous w»»t«i
1.116-
n
ni
rv
V
VI 33
(Dl
(D)
(D)
(Dl
(Dl
mi
mi
mi
031
mi
VD
vni
Notu
(D) - witbl
DC
X
kid to iral for iaHrUatl
(Dl
ccnfNUto.
mi
FocterU SDtll. Inc. compUiOom u«J utlydl of «UB nunii icponcd duUng Ux lodwiy
11-154
-------
TABLE II- 4] (1)
ESTIMATED 1974 GEOGRAPHIC DISTRIBUTION
OF WASTES FOR THE SPINNING OPERATIONS
OF THE PLASTIC MATERIALS AND SYNTHETICS INDUSTRY --
SIC 262 (WET BASIS!(KKg/YEAR)
NYLON 6
IV
X
rx
VI
IX
vm
i
m
rv
rv
DC
X
V
V
VII
vn
rv
VI
i
ni
i
V
V
IV
vn
vni
VH
DC
i
ii
VI
n
IV
vin
V
VI
X
m
i
rv
vin
rv
VI
VIE
i
m
X
in
v
vm
Potentially (1) Potentially (1)
Total H»tardous Total Hazardous
Wastes Wastes Wastes Wastes
Alabama (D) mi
Alaska
Arizona
Arkansas
California
Colorado
Connecticut
Delaware m) (D)
Florida fD) ,D)
Georgia fD, (D)
Hawaii
Idaho
Illinois
Indiana
Iowa (D) mi
Kansas
Kentuckv
Louisiana
Maine
Maryland (D) (D)
Massachusetts
Michigan
Minnesota
Mississippi
Missour:
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York (D) (D)
North Carolina (D! (D)
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania (D) (D)
Rhode Island
South Carolina (D) (D)
South Dakota
Tennessee (D) (Dl
Texas
Utah
Vermont —
Virginia (D) (D)
Washington
West Virginia fD) (DJ
Wisconsin
Wyoming
TOTAL 116,850 16,532
Region I _ _
HI 40.125 5.537
IV 76.375 10.540
V
Potentially ID
Total H»i»rdou6
Wastes Wastes
(Dl
(D)
(D)
ID)
(D)
fD)
(Dl
(Dl
(D)
fD)
(D)
706,400
(Dl
31.350*
299.750-
fD)
V!
vn (D) (D) . .
vni
Noir
(D) =
(11
rx _
X
"wiililtlli 10 »void <)iscioa..B ficuir:. It* m
-------
TABLE D- 41 (2)
IV
DC
VI
K
vin
i
ni
IV
IV
a
X
V
V
VII
vn
rv
VI
i
m
i
V
V
IV
vn
vin
VII
DC
I
II
VI
D
rv
vin
V
VI
X
m
rv
vin
rv
VI
vin
i
m
X
ni
V
vrn
CELLULOSE
ACRYLICS ACETATE
Potentially Potentially I11
Total Hazardous Total Hazardous
Wastes Wastes Wastes Wastes
Alabama (D) d»
Arizona -
Arkansas
California ..__„
Colorado
Connecticut - —
Delaware
Florida CD) (D)
Georeia <°>
Hawaii ____
Idaho
Illinois ^^__
Indiana
Kansas
Kentucky
Louisiana —
Maine .
Maryland E>
Massachusetts
Michigan _ _
Minnesota
Mississippi
Missouri . ,
Montana __
Nebraska
Nevada —
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon —
Pennsylvania W)
Rhode Island
South Carolina (D) (D) (D)
South Dakota
Tennessee (D) (D) CD)
Texas
Utah
Vermont
Virginia (D) (D) fD)
Washington
West Virginia
Wisconsin
Wyoming
TOTAL 347.500 Z78.000 S30
RAYON
Potentially
Total Hazardous
Wastes Wastes
ffi) ~
rcr roi
OH TO)
5. (80 5.860
Region I
n
HI (D) (D) 184
IV fD) (D) 146
CD) ID)
ID) TDJ
V
VI
vn
vni
DC
X
(D) * WlthlKld to avoid ducloting fipurcs for indivi«Ju«S companict.
(U Mo>eiemjJl)y hirarUout wutci
ten roe Fwtcr XX Sacll. Inc. compiUoora and aiulytu of wane ncanu fcponcd dvnng the indus
11-156
-------
TABLE IM2
TOTAL ESTIMATED WASTES FOR THE
PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY -- SIC 2B2
(WET BASIS)(KKg/YEAR)
.(2)
Potentially
Total Hazardous Total
Wastes Wastes WastaB
rv
X
IX
VI
DC
VID
I
ni
IV
rv
DC
X
V
V
VII
VII
rv
VI
i
DJ
i
V
V
rv
vn
VIII
VII
IX
i
ii
VI
ii
rv
vin
V
VI
X
III
I
rv
VID
rv
VI
VIII
i
in
x
ui
v
VID
Alabama
Alaska
A ri z on a
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Hawaii
Idaho
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Virginia
Washington
Wisconsin
TOTAL 1,
Region 1
ni
rv
V
VI
vn
vni
_PX
X
42,
1,
1,
4.
1,
24,
10,
J,
4?
Kh ,
43
f)R
7*1
5
j
Mi
?P
91.
385*
(Dl
704-
£D)
050+
(D)
£89*
381 +
116
433-
8+
(D)
(D)
10+
779+
(D)
10+
377+
420+
roi
fD!
fD)
fD)
218 +
726+
5'58»
686*
(£'
571*
420-
996*.
250+
JM+_
787+
(D!
2.
a
929
n
(IS
11
IftR
28
713+
770-
,317+
,051 +
,987
.423+
.311+
J76+
.351*
298 +
,704 +
, 807+1
335+
fD)
38.510+
(D)
252+
fD)
1-
386+
3.430
1,269+
1 +
(D)
(D)
1+
2,679+
(Dl
1 +
4,036+
3B6 +
(Dl
I'D i
\+
(D)
(D)
34.115+
65,462+
10,415+
81,684+
25 540+
_Xai2±_
1,996+
660+ _
(Dl
42.807+_.
fD) .
385+
770+
770+
1.046+
730.021
5,168+
1,818+
85.386+
40,546+
1 +
____IBJ~
28.600?
51,
1,
1,
4,
1,
29.
12,
1,
51.
79.
52,
119,
30,
6,
2,
41
31,
in.
3
4
1
2.335
16
103
112
131
34
4B6 +
CD)
672 +
(D)
271 +
(D)
823+
473+
830
734 +
10+
fD)
(D)
12+
983+
12+
556+
716+
(Dl
_J81_
ai6+ ....
(D)
BS4 +
528+
693+
412+
(D) .
S41 +
558+ . .
J0i+
443+ . .
,699+
.062 +
(Dl ...
,283
932-
.013+
,272+
.284
.242+
,226-*
.967 +
,041 +
816+
ID) ,.
Potentially
Hazardous Total
Wastes Wastes
466+
(D)
(D)
305-
P)
1+
467+
4,150
1.535+
1+
(D)
(D)
1+
3.241+
1 +
4,883+
467 +
P)
fD)
1+
(D)
(D)
... 41,278+
79,209+
12 ,602*
86.938-
30.903+
. 1.73J+...
2.415+
799+
(Dl
5}.796+
ID!
46P*
832+
(D)
1.266+
683.325
6.253+
121 839+
2.200*
20 313+
103.317+
49,061
1 +
(D)
47 807+
34.6*06+
601 +
(D)
66,616+
(D)
(D)
2,479+
610+
6.421
2.235+
12+
(D)
(D)
16+
38.665+
16+
16.188+
2,215+
(D)
(D)
6,161+
(D)
(D)
65.860+
102.533+
67,935+
153.953+
(D)
39.691+
. 3,455+
3. 514+ .
53.430+
40.869+
153.188+
.. IB' ....
4.232
1.201+
5.175+
1.639+
3.010.780
20,940+
133,085+
880,395+
145.643+
168,945+
1,181+
(D)
66,618+
45.095*
Potentially
Hazardous
Wastes
601*
(D)
61,636+
(D)
393+
(D)
2+
602+
' 5'; 351
1.980+
2+
(D)
(D)
2+
4,179
2+
6,296+
602+
(D).
(D)
2+
P)
P)
5?. 2.9+
102.121+
16.247+
127,427+
39.842+
3.114+
1.030+
_ , ,JR)
66,779+
(D)
601*
1.201+
(D)
1.138.833
6,062
157,081+
2,836+
26,189
54.735+
63,252+
+
P)
61.636+
44.616+
I,
-------
The basic factors influencing the evaluation of solid
waste volume for 1977 and 1983 are:
Production volume changes
The effect of more stringent requirements
of water pollution control.
The waste loads for 1977 are expected to vary only .with
changes in production output. The effect of the 1977 Water
Effluent Guidelines Regulations is not expected to be signifi-
cant because, as most of the plant personnel interviewed indicated,
the technology necessary to meet the 1977 requirements is already
in place. Thus, the waste factors developed in this study already
account for this technology.
For 1983, the cumulative effect of uncertainties in changes
of production volume and water regulations is such that the only
feasible approach to making the projections, at present, appears
to be to discount elements other than production growth. This
situation results because the analysis of non-water impacts of
the 1983 Water Effluent Guidelines (as presented in the Develop-
ment Documents for the relevant industries), does not appear to
provide the information necessary to evaluate realistically the
changes in waste factors per unit production. The procedure
followed for the 1983 projections is, therefore, based on changes
in production volume only.
Estimates of production for the years 1977 and 1983 were
obtained from the Interindustry Economic Research Project of
the University of Maryland (INPORUM) input/output model of the
U.S. economy. The model analyzes the economy into 200 industrial
sectors generally corresponding with the four-digit 1967 Standard
Industrial Classifications. The model, its inputs and assumptions
are discussed in Appendix A.
Table 11-43 presents production in terms of producer prices
(1972 dollars) for the years 1974, 1977 and 1983 for each of
the four-digit SICs comprising SIC 282.
11-158
-------
TABLE II - 43
PRODUCT SHIPMENTS IN PRODUCER PRICES
FOR THE PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY — SIC 282
Product Shipments in Producer Prices
( Millions of 1974 Dollars)
% Change % Change
SIC Industry 1974 1977 Over 1974 1983 Over 1974
2821 Plastic Resins 6,266 8,013 +28% 11,454 +83%
2822 Synthetic Rubber 1,345 1,489 +11% 1,605 +19%
2823 Cellulosic Manmade 681 840 +23% 933 +37%
Fibers
2824 Manmade Fibers, 3,454 4,099 +19% 5,094 +48%
Non-Cellulosic
282 Plastic Materials +21%(1> +56%(1)
and Synthetics
(1) Weighted average growth rate developed from 1974 production volume breakdown of SIC 2821,
2822, 2823 and 2824 as presented in Tables 11-12, 11-14, 11-26 and 11-28 . For example, the
contribution of SIC 2821, 2822 , 2823 and 2824 to total SIC production volume for 1974 are
38%, 17%, 2% and 43%, respectively. Thus, SIC 282 weighted average growth rate for 1977
is: (38% of 28%) + (17% of 11%) + {2% of 23%) + (43% of 19%) = 21%.
Source: INFORUM Input/Output Model, University of Maryland . June, 1975.
-------
A weighted average growth rate for the entire SIC 282
was developed based on 1974 production volume breakdown of
SIC 2821, 2822, 2823 and 2824. This growth rate for the years
1977 and 1983 are projected to be:
Rate Over 1974
Table 11-44 — Projected Average Growth
T97T
SIC 282 21% 56%
Source: Table 11-42
These growth rate factors were multiplied by the estimated 1974
wastes to project the 1977 and 1983 loads.
Total wastes for the years of interest are estimated as
follows:
Table 11-45 — Estimated Total Wastes For 1974, 1977 and 1983
(KKg/yr.)
Wet Basis Dry Basis
1974 2,751,319 1,504,469
1977 3,329,095 1,82U,407
1983 4,294,533 2,348,326
Based on an estimated industry wide total, 1974 production
of 30,472 KKKg, total wastes amount to 6% of production volume
on a weight basis.
4.4.2 Potentially Hazardous Wastes
Potentially hazardous waste quantities for 1974 by
product are presented in Table 11-40 and 11-41. Table
11-42 presents total potentially hazardous wastes for the
entire SIC 282 for the years 1974, 1977 and 1983.
11-160
-------
The information presented in these tables was arrived
at in a manner similar to that used for total wastes, as
discussed in Section 4.4.1. The values were developed by
taking the starred (*) waste factors (those considered to
be potentially hazardous) from Tables 11-46 and 11-47 for
each product and multiplying them by their respective pro-
duction from Tables II-8, 11-11, 11-32 and 11-34. Tables
11-40 and 11-41 were then totaled to produce the potentially
hazardous waste values in Table 11-42 for 1974. The values
for 1977 and 1983 were developed using the average weighted
growth factors as per Section 4.4.1.
From Table 11-42, potentially hazardous wastes for the
years of interest are summarized as follows:
Table 11-48 — Estimated Potentially Hazardous Wastes For
1974, 1977 and 1983 (KKg/Yr.)
Wet Basis Dry Basis
1974 740,351 157,347
1977 895,824 190,389
1983 1,155,614 245,602
Within SIC 282, the largest contributors to the potentially hazard-
ous land destined wastes are:
Polystyrene
Phenolics
Amino resins
Acrylics (spinning processes).
The larqest single contributor is phenolics with an estimated
366,JoogS " 1974 of an aqueous solution of phenol and formal-
dehyde as the potentially hazardous constituent.
11-161
-------
TABLE 11-46 (1)
COMPILATION OF THE REPORTED WASTE FACTORS
IN THE POLYMERIZATION OPERATIONS IN THE
MANUFACTURE OF PLASTICS AND MANMADE FIBERS
— SIC 282
Waste Streams (Kg/KKg of Product)
Rank Product(1) Class(2)
1 Polyester F
2 Polyamides F
3 Polyethylene O
H
H
1
10 4 Vinyl Resins O
5 Sryrene Butadiene O
Rubber
6 Styrene Resin O
7 Polypropylene O
8 Acrylics F
9 Phenolics R
10 Polvurethanes R
Production
KKKg/Yr.
6,855
4,727
4,018
2,277
2,216
2,244
2.19G
2,117
610
538
Type
Polyester
Nylon 6,6
Nylon 6
Low Density
! ligh Density
PVC (Emulsion)
PVAc (Latex)
Emulsion
Solution
Polystyrene
AliS-SAN
Polypropylene
Acrylics
Phenolics
Prcpolymcr
Off-Grade
Products
30
3.0
2
10
3.0
20
10
15
10
2.0
20
5.0
2.0
8
N.A.
Still Bottoms
And Waste Oils
0.1
1
0.5
1.0
1.5'
10
10
5.0'
10"
7
500 (5)
250<6>
Other
Terephthalic Acid 1.0
Spent filter and cake 0.06
Waste water sludge 3. 5
Spend adsorbent 0.006
(4)
Spent catalysr ' 0,037
Wastewater sludge 11
Wastewater sludge 3
Wastewater sludge 10
Wastewater sludge 11
Wastewater sludge (dry) 2
Nitrile waste 0 . 5
Wastewater sludge 60"
-------
TABLE H-46 (2)
Waste Streams* * (Kg/KKg of Product)
Rank
11
12
13
14
15
16
17
18
19
Product
Poly butadiene
Amino Resin
Alkyds
Neoprene
Butyl Rubber
EPM-EPDM
Coumarone- Indene
Epoxy
Silicone
cW2)
0
R
R
O
O
0
R
R
R
Production
KKKg/Yr.
477
377
317
177
166
163
148
143^
Type
Polybutadiene
Urea Formaldehyde
Alkyds
Neoprene
Butyl Rubber
EPM-EPDM
Coumarone- Indene
Epoxy
SL(11)
Total'12)
Off- Grade
Products
2
10'
1
30
None reported
None reported
None reported
90
With "other"
54
Still Bottoms
And Waste Oils
0.1*
42*
60*
(7)None reported(8)
(7)Nonereported(8)
^None reported^
30
40
58
Other
Spend adsorbent 0.1
Filter Cake 2.4*
Sweepings 0.1*
Spent Adsorbent 0.6
Spent adsorbent 0.6
Spent catalyst 0.2
Spent clay 36**10'
Spent adsorbent 5
Scrap 30
33
(1) Products are ranked in order of decreasing production tonnage.
(2) Foster D. Snell, Inc. classification symbol for polymer groups: O = Oleftnic; F = Non-olefinic, mainly used in fiber
production; R = Non-olefinic, mainly used as resin.
(3) The classes are self-evident or defined in the text.
(4) This it only for the product made by the Phillips process.
(5) Essentially • water stream containing about 7.5°t» soluble organic materials (phenol).
(6) Essentially a water stream containing about 5.0°7o soluble organic materials.
(7) Off-grade material sold for special use.
(8) Solvent recovered at production sites.
(9) The process is such that discarded stream has characteristics of #2 fuel oil.
(10)TMs figure is for the resin produced by one of several solution processes only and should not be generalized to the total production.
(11) These wastes are in addition to those reported for the gum, the bulk of which goes to rubber production and constitutes about 60%
of the finished rubber.
(12) The figures reflect the fact that only 60% of the figures for gums are additive to those for rubber.
* These streams are designated potentially hazardous.
Source: Foster D. Snell. Inc. analysis of industry interviews and literature information.
-------
TABLE D-47
Product
Polyester
Method
Melt
Off-Grade
Product
40
COMPILATION OF THE REPORTED WASTE FACTORS IN THE
SPINNING OPERATIONS IN THE MANUFACTURE OF MANMADE
FIBERS -- SICs 2823
and 2824
Waste Stream* (Kg/KKg of Product)
Waste
Water Sludges
None reported
Finishing Oils
70{1>
Other
Sand Filter 0.2
I
H1
*>.
Poly amides
Nylon 6
Nylon 6,6
Acrylics
Melt
Melt
Wet
40
4.S
SO
None reported
None reported
200**2)
None reported
1.7
Not individually
reported
Polymer
Lube oil
•
10
0.7
Cellulose Acetate
Dry Spinning
None reported
None reported
Rayon
Wet
200*
(1) Essentially a water dispersion containing 7% tu 10% organic material.
(2) This represents a sludge production typical of a salt solution process.
* These streams are designated potentially hazardous.
Source: Foster D. Snell, Inc. analysis of industry interviews and literature information.
-------
5. TREATMENT AND DISPOSAL TECHNOLOGY FOR POTENTIALLY
HAZARDOUS WASTES IN THE PLASTIC MATERIALS AND SYNTHETICS
INDUSTRY, SIC 282
In the preceding section the potentially hazardous waste
streams generated by SIC 282 have been described and quantified.
In this section these streams are correlated to the specific
disposal methods used and the adequacy of these methods assessed
in the light of three levels of technology defined below.
Level I -- Technology Currently Employed
By Typical Facilities. This level represents
the broad average treatment and disposal
practice.
Level II -- Best Technology Currently Employed.
This level represents the best practice from an
environmental and health standpoint, currently
in use in at least one location. Installations
must be commercial scale. Pilot and bench
scale installations are not suitable.
Level III -- Technology Necessary To Provide
Adequate Health And Environmental Protection.
Level III technology may be more or less sophis-
ticated or may be identical with Level I or II
technology. At this level, identified technol-
ogy may include pilot or bench scale processes
providing the exact stage of development is
identified.
The disposal methods presently encountered in this industry
are:
Incineration
Landfill
Lagooning
Storage
It should be noted that contract disposal ultimately results
in the use of one of the above methods.
The discussion of the treatment and disposal methods appli-
cable to the potentially hazardous waste streams in SIC 282 differs
somewhat from that presented in the following chapter for SIC 30
industry. The reasons are considerable differences:
in production technologies
in nature of waste streams
in disposal technology
in degree of development of potential
technologic^.
11-165
-------
In the subsequent sections the broad categories of applicable
disposal technologies are presented, followed by a detailed
discussion of treatment and disposal technology by types of
hazardous waste.
5-1 Treatment And Disposal In SIC 282
The following paragraphs discuss treatment and
disposal technologies applicable to the Plastic
Materials and Synthetics Industry. In some instances
restrictions on the permissibility of alternative dis-
posal methods may shift the disposal of certain
streams in the direction of recovery. For instance,
the additional expense of meeting adequate standards
in disposal method X, currently practiced, added to
the presently insufficient value of the recovered
product, may make recovery economically attractive.
In many instances, however, indefinite recovery
and reuse may not be feasible due to accumulation of
undesirable impurities. In this case, a portion of
the wastes is disposed of through other methods. This
appears to be the case for the disposal of zinc oxides
to landfill at certain plants of SIC 282.
5.1.2. Controlled Incineration
This method is universally practiced in the SIC
282 industries. Indeed, the fact that a waste is
incinerated may be taken as prima-facie evidence of the
undesirability of disposing of it by other methods.
However, it is not always the case. For example, incin-
eration may be more economical than landfilling because
of considerations of volume, transportation costs or
value of the waste as a fuel. An extreme case is that
of the coumarone-indene industry in which some waste
streams are indistinguishable from 12 fuel oil. At pre-
sent, state regulations are such that monitoring and
control are the rule on all incineration equipment.
Installations still lacking in these features are
scheduled to be equipped or replaced to meet the stan-
dards. Incineration can be performed on-site or
contracted out. The only reason for contracting out is
economics and thus contracting out does not represent a
technological alternative.
11-166
-------
5.1.3. Open Dumping
The majority of industry firms contacted have
become increasingly aware of their responsibility
for the proper treatment and disposal of their wastes.
They have related, during the course of the inter-
views, that they are taking an active role in investi-
gating what is occuring at their own sites as well as
those of private contractors.
5.1.4. Burial Operations And Landfills
These represent the other major disposal tech-
nology used in SIC 282 for those wastes which are
classified as potentially hazardous and which are
not incinerated. These wastes are essentially
wastewater treatment sludges contaminated by metal
ions. When inadequate landfill sites are still in
use, measures are universally being taken to im-
prove the situation by resorting to secure landfill.
Since this technology is more universally used for
SIC 30 and to avoid repetition, the detailed dis-
cussion of these operations is in Chapter III,
Section 7.3.
5.1.5. Ponding And Lagooning
This represents a technology widely used in the
production sites of SIC 282, particularly on the Gulf
Coast. However, no significant amount of potentially
hazardous wastes originating in SIC 282 operations
appear to be disposed of by this technique.
This technique provides a simple and economic
approach to on-site potentially hazardous waste disposal,
where applicable. However, there are some significant
drawbacks.
The pond must provide protection from both
surface and groundwater contamination. In
almost all areas, this requires a liner.
Liners include clay, plastic, concrete, and
epoxy, all of which are relatively expensive.
Except in very dry climates, ponds without
discharge will overflow from rainfall accu-
mulation.
Ponds are prone to be "flushed out" with
massive rainfall. It is difficult and ex-
pensive to provide flood protection.
11-167
-------
The type of production carried out at most of
the sites is such that it is impossible to evaluate
precisely the contribution to the utilization of
these facilities by processes involving SIC 282
products. At most, 5% to 10% of the streams collected
in such facilities come directly from SIC 282 opera-
tions, and in no case have these been considered po-
tentially hazardous.
11-168
-------
5.2 Treatment And Disposal In SIC 282 By Hazardous
Waste Type
It is evident from the discussion in the previous
sections that the segmentation of SIC 282 into the
Department of Commerce segments does not provide a
sound framework for the technical discussions associated
with products and processes. In particular, the dis-
tinction between SIC 2821, Plastics, and SIC 2822,
Synthetic Rubber, is inapplicable since the same
name processes (e.g., Ziegler or Phillips) are used for
some products in both segments.
5.2.1 Treatment And Disposal Of Potentially Hazardous
Wastes Generated In Phenolics Production
The phenolic resins constitute the one group in
which a substantial potentially hazardous waste problem
exists for the following reasons:
Substantial production (610 KKKg/yr)
Large volume of potentially hazardous wastes
(50% by weight)
Inadequate present long range disposal methods.
For treatment and disposal the potentially hazar-
dous wastes generated in the manufacture of phenolic
resins are separated into two streams:
A liquid stream of low viscosity, containing
organics including phenols and/or formaldehyde
easily pumpable with varying degrees of tur-
bidity
A solid/semi-solid of varying consistency which
contains oligomers and excess phenol and which
is difficult, if not impossible, to pump by con-
ventional means.
At present the practice is to incinerate the liquid
stream and to store the solid/semi-solid stream in ponds or
lagoons until a satisfactory disposal method has been
developed.
A problem associated with the incineration of the
liquid stream is that it does not contain enough organic
material to sustain its own combustion. At one of the
sites visited, a backlog of waste solvents of various ori-
gins (mostly outside the scope of SIC 282 operations)
11-169
-------
has permitted the incineration of this stream with-
out use of purchased fuel for the past several years.
However, this practice is not generally feasible.
It appears that the stream to be incinerated does not
bring elements requiring further treatment of the
combustion gases. At the other plants, this material
is generally stored on-site in drums.
Obviously, even though the precautions to pre-
vent dispersion into the environment of the solid/
semi-solid stream are presently satisfactory, storage
is not an environmentally adequate solution in the
long run. The viscosity of this material prevents its
disposal by incineration, at least in the incinerator
configurations commercially available today. Disposal
methods are reportedly under investigation. But due
to their specialized nature and the disproportionate
costs of development, these methods are kept strictly
proprietary.
5.2.2. Potentially Hazardous Waste Constituted By Partly
Unreacted Amino Resins
Equipment upsets or human error are responsible for
the wastes destined for land disposal and the need to dispose
of relatively small amounts of partly unreacted mixtures
of urea or melamine and formaldehyde. The material is drawn
off from the reactor, drummed in sealed drums and ade-
quately incinerated under contract by a professional
waste treatment firm. This, provided that the treatment
firm is aware of the potential hazard to the immediate
personnel, appears to constitute an environmentally ade-
quate disposal method. If local incineration facilities
exist, there is no reason not to dispose of this material
via that route.
5.2.3. Potentially Hazardous Waste Created By The
Handling Of Catalyst In Polyester Production
A waste stream consisting of a mixture of manganese
salts and antimony compounds has been reported by poly-
ester manufacturers. Proprietary considerations have
prevented further inquiry into the extent of this stream.
Literature confirms the use of salts of manganese, co-
balt and cadmium as catalysts in polyester production.
At present the material is stored in drums until develop-
ment of a more suitable disposal method occurs. How-
ever, technology for adequate disposal would appear
to be disposal in a secured landfill.
II-l/O
-------
5.2.4 Still Bottoms As Potentially Hazardous Wastes
Whatever their composition, the universal prac-
tice in the industry is to dispose of still bottoms
in two ways:
If the product has a merchant value -- e.g.,
amorphous polypropylene or other oligomers--
it is sold as a by-product.
If the product has no merchant value, it is
disposed of by oxidation.
Biological if biodegradable
Incineration if combustible.
Special consideration is made here of certain still
bottoms which are felt to be highly flammable and/or
to contain hazardous (possibly carcinogenic) compounds.
These are invariably incinerated. The sophistication
of the plant involved is such that in most cases the
best available equipment is used. Generally, the load
imposed on the establishment's incinerator by the sub-
ject wastes is insignificant compared to the require-
ments of other production facilities at the same loca-
tion. In some instances, recovery of heat value was a
plus, economically and ecologically.
It must be noted that, inasmuch as the practice
of controlled incineration, either on-site or by con-
tractor, is universal and most of the non-aqueous
still bottoms are essentially ash free, the bulk of this
stream can be considered presently handled with environ-
mentally adequate technology regardless of whether it is
otherwise potentially hazardous or not. The problem of
the chlorinated solvents is presently handled through
scrubbing of the off-gases and some recovery of the HCl
generated.
The net result of biological oxidation of aqueous
still bottoms containing dissolved biodegradable organ-
ics is a small production of biological sludge. It is
usually impossible to quantitatively connect this sludge
formation with the production volume. Industrial bio-
logical sludges produced from still bottoms in polymer
production are insignificant at the sites where there is
this type of water treatment.
11-171
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5.2.5. Potentially Hazardous Wastes From Cellulosic
Production
Of all the processes in this group, rayon pro-
duction is one of the most likely to generate poten-
tially hazardous wastes. Here the situation parallels
somewhat that which is encountered in the reclaimed
rubber industry which is discussed in the following
chapter; that is, at present this industry is undergoing
rapid changes. Several interviewees indicated that
they had suspended production or even abandoned produc-
tion at many of their facilities. As noted before,
economic conditions were mentioned as the reason for the
shutdowns.
The main waste problem associated with rayon
production is a waste stream containing large amounts
of zinc salts. The common practice is to adjust the
pH of the stream, to precipitate the zinc and separate
the precipitate by filtration or centrifugation. The
zinc cake (zinc oxide or hydroxide) can then be dis-
posed of in one of three ways:
Recovery and reuse in the plant
Sale for recovery off-site
Burial in secured landfill.
Economic and local conditions usually dictate the ul-
timate disposal of this zinc cake (1). In at least one
plant a very thorough study of the economics was in-
ternally performed and the local conditions were such
that the development of a secured landfill site was
found to be the most economical. However, conditions
vary and the disposal methods at other locations may be
different. It is also reported that the quantity of
zinc thus produced varies considerably depending on the
type of product and operating conditions.
5.2.6. Potentially Hazardous Wastes In Acrylic And
Modacrylic Spinning
One of the spinning methods for acrylic and mod-
acrylic fibers involves dissolution of the fibers in a
concentrated solution of metallic salts, usually zinc
chloride. The plants are usually equipped to recover
this stream. However, variable quantities resulting from
production up-sets have to be discarded, usually in
the form of oxides. The disposal method for this
stream is secured landfill.
(l)That is, if the market price of zinc is high enough it will be
recovered.
11-172
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5.2.7 Potentially Hazardous Waste Solvents In
Silicons Production
The industry structure is such that, to
preserve confidentiality, little can be said about
this stream except that it is disposed of by inciner-
ation. Since the operations investigated are carried
out in states with strong antipollution regulations,
it is assumed that incineration is carried out in an
environmentally adequate controlled manner.
11-173
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5.3. Treatment And Disposal Technology Levels As
Applied To Potentially Hazardous Wastes
Produced By The Plastic Materials And Syn-
thetics Industry, SIC 282
The levels of treatment and disposal technology
have been characterized in the opening paragraph of
Section 5. The following factors have been employed
in evaluating the technologies used or to be developed
by the industry for the treatment and disposal of
potentially hazardous wastes.
Factor I — Physical And Chemical Properties
Of The Waste. This gives a brief description
of the form of this waste and identifies the
main constituents
Factor II — Amount Of Waste (Kg/KKKg Of Product)
This factor gives an average quantity or range
of the magnitude of the total potentially haz-
ardous waste streams treated based upon a waste
factor relating the quantity of waste (kilograms)
to the quantity of production.
Factor III — Factors Affecting Degree of Hazard
From The Waste. This gives a brief description
of the possible interaction of the surrounding
environment with the waste.
Factor IV — Adequacy Of Technology. A descrip-
tion of the technology with respect to environ-
mental considerations and load regulations in
terms of present and future conditions.
Factor V -- Non-Land Environmental Impact.
This describes the possible impact of the tech-
nology on non-land environmental factors such
as water or air quality.
Factor VI — Problem Areas Or Comments.
A brief description of problem areas encountered
with the technology or important comments.
Factor VII — Compatibility With Existing
Facilities. This evaluation factor describes
whether the technology can be used by existing
plants or waste disposal contractors.
11-174
-------
Factor VIII — Monitoring And Surveillance
Techniques. This describes the type and
frequency of monitoring necessary for the
technology.
Factor IX — Installation Time For New Facility.
This factor provides information on whether or
not the treatment and disposal technology has
been installed or how long it will take to get
it on-stream.
Factor X -- Energy Requirements. This factor
describes the qualitative amount of energy
required for the technology.
With the exception of two streams, for which no
adequate technology has yet been developed, the treat-
ment and disposal practices of the SIC 282 consist of:
Secured landfill
Incineration(D
Recovery.
The treatment and disposal technologies of the
potentially hazardous waste streams discussed in Section
5.2 are applied to the three treatment and disposal
technologies in a series of tables.
Table 11-49, Liquid Phenolic Wastes
Table II-so, Solid/Semi-solid Phenolic Wastes
Table 11-51, Off-Grade Product From Amino Resin
Production
Table 11-52, Waste Catalyst Stream From Polyester
Production
Table 11-53, Still Bottoms (Aromatic, Aliphatic,
Chlorinated, Etc.) From All SIC 282
Processes Producing Such Waste Streams
Table 11-54 , Zinc Oxide Sludges From Wastewater
Treatment In Cellulosic And Acrylic
Fiber Production
Previous studies in this group identified two levels of
incineration, so-called uncontrolled and controlled. Air
pollution abatement regulations have been instituted in most
states, so that incineration as practiced in 1975 is controlled
11-175
-------
TABLE 11-49
TREATMENT AND DISPOSAL TECHNOLOGIES FOR
LIQUID PHENOLIC WASTES ~ SIC 2821
Factor
Physical and Chemical
Properties of Residual
Wastes
Amount of Residual
Wastes (Kg/KKKq Product)
Factors Affecting
Hazardousness
Treatment/Disposal
Technology
Estimate of Number or
Percent of Plants Now
Using Technology
Adequacy of Technology
Non-Land Environmental
Impact
Problems and Comments
Compatibility with Existing
ing Facilities
Monitoring and Surveillance
Techniques
Installation Tin
Facility
for New
Energy Requirements
Level I, Prevalent Technology
Water solutions of various organic
species, including phenols and/or
formaldehyde
500
Phenols and formaldehyde are toxic
to human, animal and plant life
Drum storage
50%
Inadequate
None, if drums remain sealed
Potential for drums to corrode
and spill contents
Compatible
Periodic inspection of drums to
insure they are not leaking
N.A.
None
Level III, Adequate Health
Level II, Best Available Technology And Environmental Protection
Same as Level I
Same as Level I
Same as Level I
Controlled Incinerator
50%
Adequate if air pollution control is
pratical
Same as Level I
Necessity to "burn" large amounts of
water, excessive costs and fuel
consumption
Same as Level I
Air monitoring
1 Year
600 K Cal/Kg(1,100 BUT/lb.)
Same as
Level II
Source: Foster D. Snell, Inc., analysis of company interviews.
-------
TABLE 11-50
TREATMENT AMD DISPOSAL TECHNOLOGIES FOR
SOLID/SEMI-SOLD PHENOLIC WASTE
-j
-o
Factor
Physical and Chemical
Properties of Residual
Hastes
Amount of Residual Wastes
(Kg/KKKq Product)
Factors Affecting
Hazardousness
Treatment/Di sposa1
Technology
Estimate of Number or
Percent of Plants Now
Using Technology
Adequacy of Technology
Non-Land Environmental
Impact
Problems and Comments
Compatibility vith Existing
Facilities
Monitoring and Surveillance
Techniques
Installation Time for New
Facility
Energy Requirements
Level I, Prevalent Technology
Putty-like substances with phenolic
odors. Oligomers and excess phenol
68
Toxicity resulting from the presence
of phenols
Storage in drums or concrete lined
lagoons
100%
Inadequate
Odor problems
Limited storage space, leaching into
ground or surface water
Compatible
None
Short
None
Level II, Best Available Technology
Level III, Adequate Health
And Environmental Protection
t
Same as Level I
Same as Level I
100%
No method is presently
available
Same as Level I
Same as Level I
Source: Foster D. Snell, Inc., analysis of company interviews.
-------
TABLE II- 51
TREATMENT AND DISPOSAL TECHNOLOGIES FOR
STILL BOTTOMS (AROMATICS, ALIPHATICS, CHLORINATED,
ETC.) (1)IN ALL SIC 282 PRODUCING SUCH WASTE STREAMS
•J
00
Factor
Physical and Chemical
Properties of Residual
Wastes
Amount of Residual
Wastes (Kg/KKKg Product)
Factors Affecting
Hazardousness
Treatment/Disposal
Technology
Estimate of Number or
Percent of Plants Now
Using Technology
Adequacy of Technology
Non-Land Environmental
Impact
Problems and Comments
Compatibility with Existing
Facilities
Monitoring and Surveillance
Techniques
Installation Tin
Facility
for New
Energy Requirements
Level I, Prevalent Technology
Viscous liquids, hydrocarbons
(aromatics, chlorinated)(ash
free)
Varying with the individual
product stream
Flammable solvents — human,
animal and plant life toxicity
(carci nogenicity)
Controlled incineration
100% (see "Compatibility")
Adequate
None, if incineration is
controlled
None, in well designed and
maintained equipment
Certain operations are on too
small a scale to justify in-
stallation of facilities. Contract
incineration is preferred
Automatic flame control.
gas analysis
Stack
6 mo. - 1 year on-site depending
on size
In general self-sustaining.
times minimal amount of auxiliary
fuel
Level II, Best Available Technology
Same as Level I
Same as Level I
Same as Level I
same as Level I
100%
Adequate
None, if incineration
is controlled
Same as Level I
Level III, Adequate Health
And Environmental Protection
Same as Level I
Same as Level I
Same as Level I
Present Technology
100%
Adequate
None, if incineration
is controlled
Same as Level I
(1)
The facilities are universally used indiscriminately and simultaneously for hazardous and non-hazardous wastes and are perfectly
adequate for either. The so-called "potentially hazardous" wastes of SIC 282 disposed of by incineration do not require control
technology in the incinerators. This technology is, however, generally incorporated since the burners are also used for other
products.
Sourcei Foster D. Snell, Inc., analysis of company interviews.
-------
TABLE II-<52
TREATMENT AND DISPOSAL TECHNOLOGIES FOR
OFF-GRADE PRODUCT IN AMINO RESIN PRODUCTION
-- SIC 2821
-j
VD
Factor
Physical and Chemical
Properties of Residual
Wastes
Amount of Residual Hastes
(Kg/KKKg Product)
Factors Affecting
Hazardousness
Treatment/Disposal
Technology
Estimate of Number or
Percent of Plants Now
Using Technology
Adequacy of Technology
Non-Land Environmental
Impact
Problems and Comments
Compatibility with Existing
Facilities
Monitoring and Surveillance
Techniques
Installation Time for New
Facility
Energy Requirements
Level I, Prevalent Technology
Semi-solid to solid material
containing excess formaldehyde
10
Formaldehyde fumes
Drumming at site followed
by contract incineration
by controlled equipment
100%
Adequate
None
See footnoted)
See footnoted)
As required by local
ordinances
N.A.
Negligible
Level III, Adequate Health
Level II, Best Available Technology And Environmental Protection
Same as Level I
Same as Level I
Same as Level I
See footnote (1)
Same as Level I
Same as Level I
Same as Level I
Same as Level I
See footnote (1)
Same as Level I
' 'Basically, all such streams can be incinerated. Disposal by contract incineration is subject to the same conditions of volume
considerations. Conceivably some production sites may have local incineration, usually by reason of other production. Such
situation cannot be construed as Level II, because contract incineration is, by definition, environmentally adequate.
N.A. = Not Applicable
Source: Foster D. Snell, Inc., analysis of company interviews.
-------
TABLE II- 53
TREATMENT AND DISPOSAL TECHNOLOGIES FOR
WASTE CATALYST STREAM IN POLYESTER PRODUCTION
— SIC 282
00
o
Factor
Physical and Chemical
Properties of Residual
Wastes
Amount of Residual Wastes
(Kg/KKKg Product)
Factors Affecting
Hazardousness
Treatment/Disposal
Technology
Estimate of Number or
Percent of Plants Now
Using Technology
Adequacy of Technology
Non-Land Environmental
Impact
Problems and Comments
Compatibility with Existing
Facilities
Monitoring and Surveillance
Techniques
Installation Time for New
Facility
Energy Requirements
Level I, Prevalent Technology
Solid mixture of mineral salts,
crystals and powders (proprietary)
Negligible(1)
High toxicity and solubility of
catalyst
Storage in drums
100%
Inadequate
Potential leaching of water into
ground or surface waters
Bothersome stream, too small to
warrant development of a technology:
too large to ignore
N.A.
Periodic inspection of containers
N.A.
N.A.
Level II, Best Available Technology
Same as Level I
Level III, Adequate Health
And Environmental Protection
Same as Level I
Sane as Level I
Same as Level I
Adequate technology
unavailable at present
'1'Inclusion of this stream in this study is due to the high toxicity of the materials involved and the reported present lack of
disposal technology. The total amounts represent at most a few dozens of 55 gallon drums at major production locations.
N.A. - Not Applicable
Source: Foster D. Snell, Inc., analysis of company interviews.
-------
TABLE 11-54
TREATMENT AND DISPOSAL TECHNOLOGIES FOR ZINC
OXIDE SLUDGES FROM WASTEWATER TREATMENT
IN CELLULOSIC AND ACRYLIC FIBER PRODUCTION
— SIC 2824
l-l
M
I
I—
CD
Factor
Physical and Chemical Properties of
Residual Wastes
Amount of Residual Wastes
(Kg/KKKg Product)
Factors Affecting Hazardousness
Treatment/Disposal Technology
Estimate of Number or Percent of
Plants Now Using Technology
Adequacy of Technology
Non-Land Environmental Impact
Problems and Comments
Compatibility with Existing
Facilities
Monitoring and Surveillance
Techniques
Installation Time for New
Facility
Energy Requirements
Level I, Prevalent Technology
Watery solids and semi-solids con-
taining large amounts of zinc oxide
Variable depending on operating
conditions
Potential leaching of zinc ion
into ground and surface
Secured landfill
Variable, depends on economics
Adequate if landfill is secured
Potential dispersion of zinc ion
into ground and surface water
The industry is acutely aware of
leaching problem. Practically all
the sludge is being disposed off
properly.
Compatible
Monitoring of ion concentration
at landfill sites
Variable depending on locations;
Up to 1 to 2 years
Minimal
Level II, Best Available Technology
Same as Level I
Same as Level I
Same as Level I
Recovery (2)
Variable depends on economics
Adequate
None, if appropriate control
equipment is installed on recovery
facilities.
Preferrable technology from
environmental standpoint both
directly and indirectly.
Installation of on-site recovery
facilities may be impossible due
to space limitations.
Appropriate control of streams from
the recovery process
1 Year
Minimal
Level III, Adequate Health
And Environmental Protection
Same as Level II
(l)The selection of disposal technology is a matter of economics. It varies not only from plant to plant but in time at the same point
in function of the variations of market prices for zinc and zinc salts.
(2)Recovery takes two forms, on-site and off-site. From technology standpoint the two course are equivalent.
Source: Foster D. Snell, Inc., analysis of company interviews.
-------
6. COST ANALYSIS FOR THE TREATMENT AND DISPOSAL OF
POTENTIALLY HAZARDOUS WASTES IN THE PLASTIC MATERIALS
AND SYNTHETICS INDUSTRY, SIC 282
The cost analysis is presented illustratively. As explained
several times in this report, the existence of a well-defined and
self-contained production facility for most of the products of
this industry is the exception rather than the rule. At most
locations facilities are shared with those required to handle
the wastes of other products. These "co-products" may belong
to the SIC 282 or in entirely different classifications.
A case in point is the generally practiced method of
incineration of the organic wastes, particularly liquids.
Seldom does the magnitude of streams created by the production
of a given resin (e.g., polypropylene) at one site justify the
installation and operation of the appropriate treatment and
disposal equipment.
Thus, the streams, whether solid or liquid, potentially
hazardous or non-hazardous in the sense of this study, are
handled as a part, most often small, of the general treatment
and disposal system of the production site.
For example one particularly cooperative interviewee
provided incineration cost figures calculated at several
dollars per pound incinerated. Further inquiry revealed that
the reported costs were those of the total incineration
facility at the site. The particular streams of interest
constituted only a minute fraction of the load of the facility.
The same observation applies to wastewater treatment facilities
and, therefore, to the disposal of sludge generated.
The estimates presented were prepared on an engineering
basis, using accepted engineering format. No attempt was made
to prepare estimates which would reflect impact on the financial
statements of individual companies. Inclusion of tax consider-
ations, product pricing, and other such factors would involve
practices unique to each company and should be recognized as
beyond the scope of this report.
Wherever possible, the figures have been cross checked
with actual experience in the field as reported by the firms
interviewed. However, it must be stated again that this
analysis remains purely illustrative.
11-182
-------
Bearing in mind the above discussion, evaluation of the
costs have been made using the factors outlined below. The
section following presents individual case studies for the
costs of treatment and disposal of potentially hazardous
wastes generated by this industry.
6.1 Cost Elements And Treatment Of Costs
For the purposes of this study, two kinds of costs
are presented:
Investment costs
Annual costs.
The development and treatment of these costs are presented
in the following paragraphs, supplemented where necessary
by further information detailed in each of the individual
cases beginning in Section 6.2.
6.1.1 Investment Costs
These typically represent "front end" costs
incurred only once during the acquisition of the
required land, buildings and equipment.
The importance of the landfill operations (land
intensive) is reflected by the subcategorization of
the investment costs into "land" and "other." A
nominal land cost of $12,500 per 10,000 m2 ($5,000
per acre) is used throughout, based on the results
of field contacts.
6.1.2 Annual Costs
The two basic groups of annual cost are:
first, an annualized cost of investment as defined
above and, in this study, called "capital;" and
second, other costs. The usual practice is to
subdivide these other costs in terms of materials,
utilities, labor, maintenance, supplies, insurance,
etc.
For the purpose of this study, a different
characterization is used:
Capital
Operating
Contractor
Energy and power.
11-183
-------
This reflects the different nature of the operations
involved and the particular interest of the EPA. The
composition of these cost elements is indicated below.
6.1.2.1 Capital Cost (Annual)
This is a conversion of the investment cost
to an annual sum by application of the conventional
Capital Recovery Factor as given in standard account-
ing manuals. Unless otherwise indicated, the factor
used here is 0.163, corresponding to an interest of
10% for a recovery period of 10 years. Implicit is
the assumption that the value of the investment is
zero at the end of the period. Although this may
be valid for specialized equipment (such as incinera-
tors), it does not usually correspond to agreed
practices for land and buildings. However, this
assumption appears legitimate if, in particular, the
land area devoted to landfill is initially calculated
for a 10-year capacity. In most instances, the value
of the land thus utilized is indeed nil at the end
of the fill. Rehabilitation costs of landfill sites
to alternative use are estimated to be well in excess
of the initial land value in the majority of cases,
especially for sites where potentially hazardous
wastes have been placed.
6.1.2.2 Operating Costs
In this study, this includes all the variable
costs (materials, labor, supplies, maintenance, etc.),
except the cost of fuel or electricity.
Labor costs are taken as $15,000 per year for
general non-supervisory personnel and $25,000 per
year for supervisory personnel. Part-time use is
prorated.
6.1.2.3 Hazardous Wastes Disposal Contractor Costs
This cost element is usually employed in lieu of
operating and capital cost or as a supplement to it.
It is an important element in the next chapter, Rubber
Products Industry SIC 30, and its magnitude there is
discussed separately. The cost used here reflects
actual experience.
11-184
-------
6.1.2.4 Energy And Power
Fuel costs are taken as $10 per barrel for
fuel oil and $0.15 per liter ($0.60 per gallon)
for gasoline. Natural gas is estimated at
$0.09 per cubic meter ($1.25 per million BTUs).
6.2 Case Study Of Potentially Hazardous Waste Treatment And
Disposal Costs
In this section, costs for the treatment and disposal of
typical potentially hazardous wastes are estimated for individual
products and waste streams based on the technologies defined
in Section 5. The following list details the products or
categories for which the costs were developed and the tables
summarize the estimates for each of the products.
Liquid Wastes From Phenolic Resin Production—
Table 11-55
Solid And Semi-Solid Wastes From Phenolic Resin
Production — Table 11-57
Still bottoms generated from the production of
Styrene Butadiene Rubber — Table 11-58
Polystyrene — Table 11-59
Acrylonitrile Butadiene Styrene — Table 11-60
Polypropylene — Table 11-61
Polybutadiene — Table 11-62
Zinc sludges from the production of
Rayon Fibers — Table 11-66
Acrylic Fibers — Table 11-69.
Detailed costs are not provided for the treatment and disposal
of solid and liquid wastes from amino resin production because
these costs are small and production techniques are so varied
that even illustrative examples would not be valid.
11-185
-------
For each of the products presented above, wherever appli-
cable, the three levels of technology or variations are also
taken into consideration.
6.2.1 Costs Of Treatment Disposal Of Liquid Wastes In
Phenolics Production
The present practice is to incinerate the water
waste stream containing 10% to 15% organics, with
additional fuel required to support combustion.
This practice is adequate from the standpoint of
direct environmental impact. However, it requires
a considerable amount of fuel to convert the water
into steam during or prior to the combustion
process.
The costs elements are:
Incineration: The cost of an incinerator of the
required capacity is estimated at about $1,000,000
installed, according to industry contacts.
Annualized capital ($1,000,000 x 0.163) = $163,000
Labor (4 man-years) = $60,000.
Fuel: The fuel requirements vary from zero, if the
stream contains more than 12% organics, to about 2,400
barrels, if it contains 5% organics. For this latter
case a cost of $24,000 per year for fill may be encoun-
tered.
Costs are summarized in Table 11-55.
6.2.2 Costs Of Treatment And Disposal Of Solid And Semi-
Solid Waste Streams In Phenolics Production
Level I. The present practice is to store the material
in drums or in secure containment until development of
suitable technology.
Level II. Incineration, made possible by the
production (at the same site) of large amounts
of other materials with which the stream is
mixed.
Level III. This is proprietary technology, said to
be under development. None presently available.
11-186
-------
Typical Plant
Phenolic Resins
Identification of
Waste Stream
Liquid fraction
from reactor condensate
TABLE 11-55
PHENOLICS PRODUCTION: TYPICAL PLANT
DISPOSAL COSTS FOR POTENTIALLY HAZARDOUS LIQUID
WASTES — SIC 2821
Production Rate
15 KKKg/yr.
Composition
Water - 85-95%
organics 5-15%
(phenols, formal-
dehyde and other
organics)
Location
Eastern U.S.
Process
Condensation
Amount To
Treatment/Disposal
8000 KKg/yr.
Dollars(1974)
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Level I
1
negligible
1,000,000
1,000,000
160,000
60,000
24,000
244,000
16.3
30.5
Level II Level III
1
negligible t
1,000,000
1,000,000
No techno]
163,000 rently avc
60,000
24,000
247,000
16.3
30.5
.ogy cur
tilable
r
Treatment/Disposal Technology
Level I Incineration with additional fuel
Level II Same as Level I
Level III Same as Level I
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-187
-------
The cost elements are:
Drum storage: Each drum contains about 200Kg
(450 Ibs.) of material. Thus, 5 drums are required
per ton of product; that is, 4,500 drums per year.
The costs are estimated at $3.25 per drum, covering
the cost of the drum, the handling and the value
of the storage space* Thus, the cost is estimated
at $16.25 per ton or about $15,000 per year.
Incineration: In this example, the stream to be
incinerated represents 5% of the capacity of the
incinerating system. Therefore, a capacity of
18,000 KKg of incineration per year is required.
The costs are allocated back on the basis of 5%
utilization of the capacity. The cost of the
required incinerator is estimated at a total of
$4,000 000. It requires four-man operation and
one supervisor. Total labor costs: $85,000.
Auxiliary fuel required is estimated at 5 barrels
per day. Maintenance (at 1% of installation)
costs $40,000 per year. The fuel costs would
thus be about $12,000 per year. The share borne
by the incineration of the subject stream is
given in the following table.
Table 11-56 — Incineration Costs In Phenolics Production
Investment ($4,000,000 x 0 05) $200,000
Cost of capital ($200,000 x 0.16) 32,000
Operating cost ($125,000 x 0.05) 6,250
Fuel cost ($12,000 x 0.05) 600
Total $238,850
Proprietary Technology Development: The technology
for this level is reported under development. Costs
and other data are highly proprietary. It should,
however, present a substantial economic advantage
over present practice.
Costs are summarized in Table 11-57.
6.2.3 Costs Of Treatment And Disposal Of Still Bottoms In
A SBR Plant
All that is required for the environmentally adequate
disposal of this waste is the existence of a large enough
pool of mixed material to be burned (incinerated) so that
the flame adjustment does not have to be changed frequently.
11-188
-------
TABLE 11-57
PHENOLICS PRODUCTION: TYPICAL PLANT
DISPOSAL COSTS FOR POTENTIALLY HAZARDOUS SOLID AND
SEMI-SOLID WASTES—SIC 2821
Typical Plant
Phenolic Resins
Identification of
Waste Stream
Solid sediments from
realtor condensate
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Production Rate
15 KKKg/yr.
Composition
Varying amounts
of products sol-
vents and water
Level I
1
15,000
15,000
1.0
16.
Location Process
Eastern U.S. Condensation
Amount To
Form Treatment/Disposal
Putty like 900 KKg/yr.
substance
Dollars (1974)
Level II Level III
1
/
200,000
200,000
No technology cur
32,000 rently available
6,250
600
38,850
2.59
43.2 M
Treatment/Disposal Technology
Level I Drum storage
Level II Incineration together with other materials
Level III None available
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-189
-------
The cost elements are:
The average plant may have to burn about 5.6 Kg of
still bottoms per 1,000 Kg of product. With a
production of 60.4 KKKg per year, this represents
about 200,000 Kg of product per day or 1,000-1,500
Kg of still bottoms. This is 1,500 liters per day
(400 gallons per day) or almost 8 drums.
The required incinerator is comparatively very small.
The cost is about $50,000 installed. It requires
less than 1/4 man-day for operations. No significant
auxiliary fuel is required and less than $1,000 per
year of maintenance is necessary.
It is to be noted that in real life this would not
necessarily be the case. The stream could in fact be
disposed of:
As auxiliary boiler fuel
- As a small part of a much larger feed stream
to a centralized facility.
The costs presented here are illustrative and are
summarized in Table 11-58.
6.2.4 Costs Of Treatment And Disposal Of Still Bottoms In
A Polystyrene Plant
The still bottom produced in this operation is
substantially similar to that for the SBR plant previously
described. The production of still bottoms is about 10 Kg/
KKg of product. The production is about 56 KKKg per
year and about 560 KKg of still bottoms are produced. This
requires an incinerator of about the same capacity as for
the previous plant. However, it is assumed that it will
be operated about twice as long. To account for this
difference (two shifts/5 days per week instead of one shift),
the labor requirements are estimated at 1/2 man-year and
the maintenance costs increased to $1,500 per year.
The costs are summarized in Table 11-59.
6.2.5 Costs Of Treatment And Disposal Of Still Bottoms In
ABS-SAN Plant~
The equipment requirements and costs are the same
as for the previously described plant. The typical plant
produces 130 KKKg of resin per year and disposes of 650
KKg of still bottoms per year. The equipment, operating
and maintenance costs should be about the same as for the
polystyrene plants. The unit costs reflect the small
difference in actual production volume and quantity of
wastes generated.
The costs are summarized in Table 11-60.
11-190
-------
TABLE 11-58
STYRENE BUTADIENE RUBBER: TYPICAL PLANT
DISPOSAL COSTS FOR POTENTIALLY HAZARDOUS STILL
BOTTOMS — SIC 2822
Typical Plant
Styrene butadiene rubber
Identification of
Waste Stream
Still bottoms from
monomer and solvent
recovery
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Production Rate
60.4 KKKg/yr.
Composition
Organics
Aromatics
Level I
1
negligible
50,000
50,000
8,000
5,000
negligible
13,000
0.22
35.9
Location
Gulf Coast
Form
Liquid
Dollars (1974)
Level II
1
negligible
50,000
50,000
8,000
5,000
negligible
13,000
0.22
35.9
Process
Polymerization
50% solution 50%
emulsion
Amount To
Treatment/Disposal
362.4 KKg/yr.
Level III
negligible
50,000
50,000
8,000
5,000
negligible
13,000
0.22
35.9
Treatment/Disposal Technology
Level I Controlled incineration
Level II Controlled incineration
Level III Controlled incineration
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-191
-------
TABLE 11-59
POLYSTYRENE: TYPICAL PLANT DISPOSAL COSTS FOR
POTENTIALLY HAZARDOUS STILL BOTTOMS —
SIC 2821
Typical Plant
Polystyrene
Identification of
Waste Stream
Still bottoms
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Production Rate
55.9 KKKg/yr.
Composition
Organics
Aromatics
Level I
1
negligible
50,000
50,000
8,000
9,000
negligible
17,000
0.30
30.4
Location
Ohio
Form
Liquid
Dollars (1974)
Level II
1
negligible
50,000
50,000
8,000
9,000
negligible
17,000
0.30
30.4
Process
Polymerization
Amount To
Treatment/Disposal
559 KKg/yr.
Level III
negligible
50,000
50,000
8,000
9,000
negligible
17,000
0.30
30.4
Treatment/Disposal Technology
Level I Controlled incineration
Level II Controlled incineration
Level III Controlled incineration
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-192
-------
TABLE 11-60
ABS-SAN RESINS: TYPICAL PLANT DISPOSAL COSTS
FOR POTENTIALLY HAZARDOUS STILL BOTTOMS
— SIC 2821
Typical Plant
ABS-SAN
Identification of
Waste Stream
Still bottoms
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Production Rate
130 KKKg/yr.
Composition
Aromatic s and
other Organics
Level I
1
50,000
50,000
8,000
9,000
negligible
17,000
0.13
26.1
Location
Ohio
Form
Liquid
Dollars (1974)
Level II
1
50,000
50,000
8,000
9,000
negligible
17,000
0.13
26.1
Process
Polymer i zation
Amount To
Treatment/Disposal
650 KKg/yr.
Level III
50,000
50,000
8,000
9,000
negligible
17,000
0.13
26.1
Treatment/Disposal Technology
Level I Controlled incineration
Level II Controlled incineration
Level III Controlled incineration
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-193
-------
6.2.6 Cost Of Treatment And Disposal Of Still Bottoms In
A Polyproplyene Plant
Here again the costs presented are illustrative. At
an integrated production site, for instance, it was found
that the incinerator used for the liquid organic wastes
had a capacity of 6,500 KKg per year; had cost $3,200,000
(1974 dollars); and had an operating cost (excluding capital
cost of $160,000 per year. Thus, in the terms of this
study, it had an annual cost of $672,000 per year. With
the average polypropylene installation used for this study,
933 KKg of still bottoms would be produced by the
polypropylene unit. The prorated costs would then be
about $96,000 for this particular site. It is to be noted
that, of these costs, $62,000 are costs of capital, as
computed for this study. These figures differ considerably
from those which were allocated to the polypropylene stream
at that location.
Should an installation be provided for the estimated
still bottom stream of 933 KKg per year, it is estimated that
a comparatively small burner--3,000 Kg per day or, say,
$3,000 per day (150 gallons)—could be used. A unit of
this type would probably cost about $75,000. Given 1/2
man-year of operation and about $1,500 per year of
maintenance, the operating cost would be about $9,000
per year. The cost of capital would be $12,000, and the
total annualized costs would be $21,000.
These costs are summarized in Table 11-61.
6.2.7 Cost Of Treatment And Disposal Of Still Bottoms In
A Polybutadiene Plant
Again, the polybutadiene production facility would
in reality be part of a large production complex of which
it would constitute only one unit; it would share feed-
stock and services with the other utilities.
However, in this case, the extreme smallness of the
still bottom stream, estimated at only 4.8 KKg per year,
would permit another solution.
Such a small stream cannot justify the installation
of an incinerator in the hypothetical case of a single
standing plant. In this case the practice would be to
contract the incineration. In another study, currently
being performed for the EPA, Foster D. Snell has obtained
data indicating an average national cost of $0.12-0.15
per gallon for contract incineration of combustible
liquid waste. This averages to about $50 per KKg of
waste and is the basis of the costs presented in Table
11-62.
11-194
-------
Typical Plant
Polypropy1ene
Identification of
Waste Stream
TABLE 11-61
POLYPROPYLENE: TYPICAL PLANT DISPOSAL COSTS
FOR POTENTIALLY HAZARDOUS STILL BOTTOMS
— SICS 2821 and 2824
Production Rate
93.3 KKKg/yr.
Composition
Location
Texas
Form
Process
Polymerization
Amount To
Treatment/Disposal
Still bottoms
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Organics
Aliphatics
Level I
1
negligible
75,000
75,000
12,000
9,000
21,000
0.22
22.0
Liquid
Dollars (1974)
Level II
1
negligible
75,000
75,000
12,000
9,000
21,000
0.22
22.0
933 KKg/yr.
Level III
negligible
75,000
75,000
12,000
9,000
21,000
0.22
22.0
Treatment/Disposal Technology
Level I Controlled incineration
Level II Controlled incineration
Level III Controlled incineration
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-195
-------
TABLE 11-62
POLYBUTADIENE: TYPICAL PLANT DISPOSAL COSTS
FOR POTENTIALLY HAZARDOUS STILL BOTTOMS
— SIC 2822
Typical Plant
Polybutadiene
Identification of
Waste Stream
Still bottoms
Production Rate
47.7 KKKg/yr.
Composition
Organics
Aliphatics
Location
Texas
Form
Liquid
Process
Polymerization
Amount To
Treatment/Disposal
4.8 KKg/yr.
Dollars(1974)
T/D Level
Level I
Level II
Level III
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
250
0.05
50
250
0.05
50
250
0.05
50
Treatment/Disposal Technology
Level I, II, III - Contract incineration (controlled)
Source; Foster D. Snell, Inc., analysis of interviews and literature data.
11-196
-------
6.2.8 Costs Of Treatment And Disposal Of Sludge Containing
Zinc In A Rayon Plant
In the United States six plants manufacture rayon.
The typical plant produces 60 KKKg (132,000,000 Ibs.)
per year. Such a plant has to dispose of 12,000 KKg
(26,400,000 Ibs.) of zinc containing sludge per year.
This represents about 10,000 m3 (13,000 cu. yds.) of
sludge per year.
This sludge contains about 10% zinc hydroxide; that
is, 1,200 KKg (2,640,000 Ibs.)
The cost elements are:
Level I. This technology consists of disposal to
secured landfill. The operating costs for a secured
landfill at a typical production site amount to
Labor: $1,500/1000 m3
Fuel: $500/100 m3
The investment for a secured landfill, exclusive of
land, is estimated at $125,000 per 10,000 m2 ($50,000/
acre). This includes excavation, drainage, test wells
and a prorated volume as utilized for the sludge.
The yearly land requirement is 2,000 m2 (0.5 acre).
The landfill site is assumed to be prepared for a
10-year capacity. Thus, a land area of 20,000 m2
(5 acres) is required. The land value is estimated
at $12,500 per 10,000 m2 ($5,000/acre). The cost of
disposal estimated by this method is given in the
following table.
Table 11-63 — Level I Disposal Costs In Rayon
Production
Investment costs
Land (20,000 m2 @ $1.25/m2) $ 25,000
Other (20,000 m2 @ $12.5/m2) 250,000
Total $275,000
Annual costs
Capital costs ($275,000 x 0.16) $ 44,000
Operating costs ($2,000 @ $1.50) 3,000
Fuel costs ($2,000 <§ $0.50) 1,000
Total $ 48,000
11-197
-------
Level II. This involves the installation of a zinc
recovery unit.
The cost of such a unit treating 20,000 n»3 per year
is reported to be $2,750,000.
Using the convential engineering scaling factor,
0.6 power of the size, the cost of a recovery plant
treating 10,000 m3 of sludge per year is estimated
at $1,800,000.
The operating costs of the 20,000 m3 per year unit
are reported to be $125,000 per year. These represent
mostly labor costs. Thus, the cost of operating the
smaller plant is estimated at $100,000. The energy
costs are considered to be almost $2,000 per year.
The costs of operating the recovery unit are summarized
in the following table.
Table 11-64 — Level II Operating Costs For Zinc Recovery
Unit In Rayon Production
Investment costs Negligible
Other $1,800,000
Total $1,800,000
Annual costs
Capital costs ($1,800,000 x 0.16) $ 288,000
Operating costs 100,000
Fuel 2,000
Total $ 390,000
However, the plant recovers the zinc chloride.
The net value of the material thus recovered
(after deduction of the cost of the required
hydrochloric acid and adjustment for 90% yield
of recovery) is estimated at $1,100,000.
The process is reported to reduce the volume
of sludge to 1/3 the original. Therefore, the
disposal of 3,300 m3 per year has to be taken
into account.
Based on the same assumptions and estimates as
used with regard to Level I disposal, the cost
of disposing of this sludge is estimated in the
following table.
11-198
-------
Table 11-65 — Level II Disposal Costs In Rayon
Production
Investment costs
Land (7,000 m2 @ $1.25/m2) $ 9,000
Other (7,000 m2 @ $12.5/m2) 88,000
Total $ 97,000
Annual costs
Capital costs (1,897,000 x 0.16) $303,000
Operating costs 101,050
Fuel 2,350
Total $406,400
The operation thus appears to achieve a net
operating profit of about $700,000 per year.
Level III. Since both Level I and Level II
technologies are considered environmentally
adequate, they each represent Level III
technologies. Therefore, Level Ill-technology 1
is estimated to be the same as Level I and
Level Ill-technology 2 is the same as Level II.
All the cost data are summarized in Table 11-66.
6.2.9 Costs Of Treatment And Disposal Of Zinc Containing
Sludge In Acrylic And Modacrylic Plants
The typical acrylic/modacrylic processing plant has
a production level of 130 KKKg (290,000,000 Ibs.) per
year. It produces about 26,000 KKg of zinc containing
sludges. This represents about 24,000 m3 (31,000 cu. yds.)
per year. '
This sludge contains about 5% of zinc hydroxide.
This would represent about 1,300 KKg per year.
The disposal of this sludge is identical to
disposal methods practiced in the rayon plant, as
described in the preceeding sub-sections.
11-199*
-------
TABLE 11-66
RAYON: TYPICAL PLANT DISPOSAL COSTS FOR
ZINC CONTAMINATED SLUDGE — SIC 2823
Typical Plant
Rayon
Identification of
Waste Stream
Production Rate
60 KKKg/yr.
Composition
Location
South Eastern
U.S.
Form
Process
Viscose
Amount To
Treatment/Disposal
Zinc contaminated
sludge
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Water 75%
Solids 25%
Zinc Hydroxide 10%
Level I
1
25,000
250,000
275,000
44,000
3,000
1,000
48,000
0.80
4.00
Gel-like
Dollars (1974)
Level II
1
9,000
1,888,000
1,897,000
303,000
101,000
2,400
406,400
(11.7)
<58.3)
12,000 KKg/yr
Level
1
25,000
250,000
275,000
44,000
3,000
1,000
48,000
<1} 0.80
(1) 4.00
III
2
9,000
1,888,000
1,897,000
303,000
101,000
2,400
406,400
<11.7)(1
(58.3) (1
Treatment/Disposal Technology
Level I Secured landfill
Level II Zinc recovery and secure landfill
Level III-l Same as Level I
Level III-2 Same as Level II
(1) This figure reflects an additional profit realized from the value of the
recovered zinc chloride.
Source; Foster D. Snell, Inc., analysis of interviews and literature data.
11-200
-------
Using the same cost parameters, the following costs
can thus be estimated:
Table 11-67 -- Level I Disposal Costs In Acrylic And
Modacrylic Production
Investment costs
Land $ 60,000
Other 600,000
Total $660,000
Annual costs
Capital $105,600
Labor 7,200
Fuel 2,400
Total $115,200
Level II. Recovery
It is assumed that the plant reported is designed
to handle 20,000 m3 per year of 10% sludge and is
adequate to handle 24,000 m3 per year of 5% sludge.
It is further assumed that the same sludge volume
reduction is encountered.
The value of the recovered zinc chloride is
estimated at $1,220,000 per year. Therefore, the
recovery costs presented in the following table
result.
11-201
-------
Table 11-68 — Level II Total Zinc Recovery Costs In
Acrylic And Modacrylic Production
Investment costs
Land
Other
Annual costs
Capital costs
Operating costs
Energy costs
Total
Total
$ 20,000
2,950,000
$2,970,000
$ 475,000
125,000
3,000
$ 603,000
There is a net operating profit of $617,000.
The cost figures are summarized in Table 11-69.
6.3 Costs Of Disposal Of Potentially Hazardous Wastes Affecting
The Various Segments Of The Plastic Materials And Synthetics
Industry, SIC 282
The costs data developed for the various individual products
in the previous sections are summarized for the relevant segments
of the Plastic Materials and Synthetics Industry and presented in
Table 11-70.
The costs are in turn expressed as a percentage of the
value of the products shipped by the segments of the industry
in Table 11-71.
However, it must be borne in mind that these figures, for
all their precision, are illustrative. They would be substantially
affected by shifts in the relative importance of the various
products manufactured in each segment of the industry.
Table 11-72 presents a synopsis of the findings concerning
the potentially hazardous waste streams, their nature, the
amounts generated annually, the treatment and disposal techno-
logies and the associated costs on a product-by-product basis.
11-202
-------
TABLE 11-69
ACRYLIC AND MODACRYLIC: TYPICAL PLANT DISPOSAL
COSTS FOR ZINC CONTAMINATED SLUDGE --
SIC 2824
Typical Plant
Acrylic and Modacrylic
Identification of
Waste Stream
Zinc contaminated
sludge
Production Rate
130 KKg/yr.
Composition
Water 85-90%
Solids 10-15%
Zinc 5%
Location
South Eastern
U.S.
Form
Gel-like
Process
Wet Spinning
Amount To
Trea tment/Di sposal
26,000 KKg/yr.
Dollars (1974)
T/D Level
Technology
Investment Costs
Land
Other
Total Investment
Annual Costs
Cost of Capital
Operating Costs
Energy and Power
Contractor
Total Annual Costs
Cost/KKg of Product
Cost/KKg of Waste
Level I
1
60,000
600,000
660,000
105,600
7,200
2,400
-
115,200
0.89
4.43
Level II
1
20,000
2,950.000
2,970,000
475,000
125,000
3,000
-
603,000
(4.75) (1)
(23.73) (D
Level
1
60,000
600,000 2
660,000 2
105,600
7,200
2,400
-
115,200
0.89
4.43
III
2
20,000
,950,000
,970,000
475,000
125,000
3,000
603,000
(4.75) (l)
(23.73) (D
Treatment/Disposal Technology
Level I Secured landfill
Level II Recovery
Level III-l Same as Level I
Level III-2 Same as Level II
(i; This represents a net operating profit due to the values of the recovered
zinc chloride.
Source: Foster D. Snell, Inc., analysis of interviews and literature data.
11-203
-------
TABLE 11-70
YEARLY EXPENDITURES FOR POTENTIALLY HAZARD-
OUS WASTE DISPOSAL IN THE MAJOR SEGMENTS OF THE
PLASTIC MATERIALS AND SYNTHETICS INDUSTRY BY T/D
LEVEL ~ SIC 282
i
to
O
T/D Level
SIC Code Product Production Wastes Technology
(KKKg/yr.) (KKg/yr.)
2821 Phenolics*1* 610 361,000
2822 Styrene Butadiene 2,116 12,700
Rubber
2821 Polystyrene 1,844 18,440
2821 ABS-SAN 440 2,200
2821 Polypropylene 1,026 10,260
2824 1,170 11,700
2823 Rayon 360 36,000
2824 Acrylics/Modacrylics 1,390(3) 278,000
2821 Subtotals
2822
2823
2824
282 Total
Note: For technology definitions see individual cost tables.
(1) This represents a summation of two waste streams: liquid and solid
(2) Net profit from zinc recovery.
(3) The wastes originate in spinnning operations only.
(4) The total reflects the net profit from zinc recovery in rayon and
production sites.
I
1
($
10.50
.46
.56
.06
.23
.26
.03
1.23
11.35
.46
.03
1.23
13.33
.
acrylics.
(5) The total includes costs of Level I technologies for those products which do
technologies.
N.A. = Not Applicable.
II
1
Million,
11.50
.46
.56
.06
.23
.26
(2.10) (2)
(6.60) <2>
12.35
.46
(2.10) (2)
(6.60) (2)
4.37(4)
Recovery
not have
III
1
1974)
11.50
.46
.56
.06
.23
.26
.03
1.23
12.35
.46
.03
1.23
14.33
is assumed at
Level III-2
III
2
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
(2.10) (2)
(6.60) (2)
12.35
.46
(2.10) (2)
(6.60)(2)
4.37<5>
all
Source: Summations of values from Tables 11-55 through 11-62, 11-64 and 11-69 and from production
tables in this chapter.
-------
Table 11-71
PERCENT OF PRODUCTION VALUE ALLOCATED TO
TREATMENT AND DISPOSAL OF POTENTIALLY
HAZARDOUS WASTE IN THE PLASTIC MATERIALS
AND SYNTHETICS INDUSTRY—SIC 282
Percent Of Production Value
H
H ,
1
O
SIC T/D Level
Code Technology
2821
2822
2823
2824
Total
I
0.25
0.042
0.0048
0.034
0.14
II
0.28
0.042
(0.33) d*
(0.18) M
0.045'1'
III
1
0.28
0.042
0.0048
0.034
0.15
III
2
0.28
0.042
(0.33)
(0.18)
(0.045
(1) These figures reflect the net profit from zinc recovery in rayon and acrylics. Recovery assumed
at all production sites.
Source; Foster D. Snell, Inc. analysis of industry interviews and literature data.
-------
Table 11-72
SYNOPSIS or THE FINDINGS ON TREATMENT/DISPOSAL
METHODS AND COSTS FOR THE PLASTIC MATERIALS AND
SYNTHETICS INDUSTRY—SIC 282
M
I
NJ
O
Ot i
o
SIC Coda
2821
2822
2821
2821
2821
2824
2823
2824
T/D •
(1)
(2)
(3)
(4)
Phenolic Resins
Styrene, Butadiene
Rubber
Polystyrene
AB8-SAN
Polypropylene
Rayon
Acrylics
Quantity of Potentially
Haste Stream Hazardous Haste Generated
Liquid fraction from
reactor condanaate
Solid sediments from
reactor condanaate
Still bottoms from
monomer and solvent
recovery
Still bottom*
Still bottoms
Still bottoms
Zinc containing sludge
Zinc containing sludge
(Wg/yr.)
325,000
36,000
12,700
18,440
2,700
22,000
7,200
278,000
Technology
Incineration
Storage
Incineration
with other
materials
Incineration
Incineration
Incineration
Incineration
Secured
landfill
Recovery
Secured
landfill
Recovery
Level (1)
1 c II
I
II-III
I-II-III
I-II-III
I-II-III
I-II-III
I-III-l
I-III-2
I-III-l
ii-m-2
Costs'"
Product
16.3
1.0
2.59
0.22
0.30
0.13
0.22
0.80
<11.7>»>
Per Plant
<$/yr.)
224,000
15,000
38,850
13,000
17,000
17,000
21,000
48,000
406,400
(700,000) (4)
0.89 115,200
(4. 75) (3> 603, 000
(1,220,000) (4)
Treatment/Disposal
See Tables 11-55 through 11-58, 11-62, 11-66 and 11-69 for complete definitions of the respective T/D
Xevels.
This is the cost for a "typical" plant, at about the average production capacity for the particular product.
This represents a net profit from the value of the recovered zinc.
This represents the value of the recovered zinc at the typical plant.
Source: Summation of the information presented in Tables 11-55 through 11-62, 11-66 and 11-69
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