,** COMMITTEE ON EPA/625/CR-02/003
THE CHALLENGES OF April 2002
MODERN SOCIETY www.nato.int/ccms
NATO/CCMS Pilot Study
Clean Products and Processes
(Phase I)
2001
ANNUAL REPORT
Number 253
NORTH ATLANTIC TREATY ORGANIZATION
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EPA/625/CR-02/003
April 2002
2001 Annual Report
NATO/CCMS Pilot Study
Clean Products and Processes
(Phase I)
Report Number 253
U. S. Environmental Protection Agency
University of Oviedo
Oviedo, Spain
i
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NOTICE
This report was prepared under the auspices of the North Atlantic Treaty Organization's
Committee on the Challenges of Modern Society (NATO/CCMS) as a service to the
technical community by the United States Environmental Protection Agency (U.S. EPA).
The views expressed in these Proceedings are those of the individuals authors and do
not necessarily reflect the views and policies of the U.S. EPA. Scientists in EPA's Office
of Research and Development have prepared the EPA sections, and those sections
have been reviewed in accordance with EPA's peer and administrative review policies
and approved for presentation and publication.
This document was produced as a result of a cooperative agreement with U.S. EPA's
National Risk Management Research Laboratory, under the direction of E. Timothy
Oppelt, and the Department of Chemical and Environmental Engineering of the
University of Oviedo. The Annual Report was edited and produced by Jane E. Ice and
Daniel J. Murray of the U.S. EPA's Technology Transfer and Support Division, and by
Jose Coca, Jose Manuel Benito and Julio R. Fernandez of the University of Oviedo.
Mention of trade names or specific applications does not imply endorsement or
acceptance by U.S. EPA or University of Oviedo.
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CONTENTS
Preface vii
Introduction ix
Welcome and Opening of the Meeting xi
Tour de Table Presentations 1
Pilot Projects Updates 33
Invited Presentations 41
Computer Demonstrations 43
Poster Presentations 47
University-Industry Co-operation Presentations 59
Special Topic Presentations on Environmental Challenges in Process Industries 65
NATO Field Trips 87
Open Forum on Clean Products and Processes and
Future Direction of the Pilot Study 89
Appendix I - List of Delegates and Participants 91
Appendix II - Program for the Meeting in Oviedo, Spain 2001 99
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
NATO/Committee on the Challenges of Modern Society
PILOT STUDY on
CLEAN PRODUCTS AND PROCESSES
4th Meeting
May 6-11,2001
Oviedo, Spain
San Hhgtti't de Lttlu
Plaza d? la Ercandolera
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
PREFACE
The council of the North Atlantic Treaty Organization (NATO) established the Committee on the
Challenges of Modern Society (CCMS) in 1969. CCMS was charged with developing meaningful
programs to share information among countries in environmental and societal issues that comple-
ment other international endeavors and to provide leadership in solving specific problems of the
human environment. A fundamental precept of CCMS involves the transfer of technological and
scientific solutions among nations with similar environmental challenges.
The concept of sustainable development, universally accepted as the means of protecting the
environment for all mankind, demands that future manufacturing technologies must be cleaner,
yet economically sound. With continued industrialization and improving standard of living
among nations, and with increasing globalization of markets and means of production, all nations
by and large are facing similar environmental challenges in the manufacturing sectors. We
established this pilot study on Clean Products and Processes to create an international forum
where current trends, developments, and know-how in cleaner technologies, and in tools for
measuring their cleanliness can be discussed, debated, and shared. We hope that this pilot study,
through its annual meetings, will help stimulate productive interactions among experts, with the
expected benefits of effective technology transfer.
The first meeting, held in Cincinnati, Ohio, on March 23-26, 1998, was devoted to creating an
agenda for the pilot study. Delegates expressed their views on factors and developments that
embody clean manufacturing products and processes. There were several guest lectures on
significant developments in government programs, academic and industrial efforts.
The second meeting of the pilot study was held in Belfast, Northern Ireland, on March 21-25,
1999. This meeting capitalized on the momentum of the first year of the pilot study, focusing on
progress made on several pilot projects being implemented by participating nations and building
a program of collaborative endeavors, including information exchange and industrial
participation in the pilot study. There were several guest lectures on significant developments in
government programs, academic research and industrial applications.
The third meeting of the pilot study was held in Copenhagen, Denmark on May 7-12, 2000. This
meeting maintained the momentum generated during the first two years of the pilot study,
focusing on progress made on several pilot projects being implemented by participating nations
and continuing to build a program of collaborative endeavors. This meeting featured a special
topical seminar titled "Product Oriented Environmental Measures", which focused participants'
attention on advances in product design and use. The meeting featured several guest lectures on
significant developments in government programs, academic research and industrial applications.
The fourth annual meeting of the NATO/CCMS Pilot Study on Clean Products and Processes
was held on May 6-11, 2001 in Oviedo, Spain. The meeting was hosted by Professor Jose Coca
Prados, University of Oviedo, Department of Chemical and Environmental Engineering, Oviedo,
Spain. The summary and conclusions reached at this meeting are presented in this report.
Subhas K. Sikdar, Pilot Study Director
Daniel J. Murray, Jr., Pilot Study Co-Director
VII
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
INTRODUCTION
During the third NATO/CCMS Pilot Study held in Copenhagen on May 7-12, 2000 the delegates
attending the meeting suggested that the fourth meeting could take place in Oviedo, Spain. After
the excellent meeting in Copenhagen, being hosted by Professor Henrik Wenzel, I was aware of
the task that I would have to do in the following year, but in spite of that, I accepted the
challenge.
A distinctive feature of this NATO/CCMS Pilot Study is to combine the presentation of research
activities (both from industry and university) in the host country, with the presentation of
environmental activities and problems in different countries. The ideas and technology transfer
that emerge from these meetings may be of particular advantage for the Environmental Agencies
of the NATO countries and the Eastern European countries. The latter ones are doing a giant
effort to renew their industry with modern technology and with the purpose of reaching a better
production efficiency and a better environment.
Clean processes and environmental issues are part on an integrated industrial design, that must be
compatible with the rising aspirations of the poor and developing countries for better economic
conditions and a higher standard of living. At the same time a key issue for industrial nations is
sustainable development: Development that meets the needs of the present generation without
compromising the ability of future generations to meet their needs. The eradication of poverty
and sustainable development will require attention to three main factors: Quality of life, Natural
resources and Environment.
The Oviedo meeting, with an attendance of 45 participants, was the largest, so far, to the
NATO/CCMS Pilot Study. This new NATO/CCMS Pilot Study report reflects most of the topics
presented at the meeting. At the end of the report as much information as possible is provided
from most of the delegates (picture included), so that it will make easier the exchange of
information and contacts with the representatives of different countries.
I am most grateful to companies and institutions from the region of Asturias that generously
supported the meeting: City Council of Oviedo, Government of the Principality of Asturias,
Bayer, Burdinola, Cajastur, Dow Chemical, and DuPont.
I have to acknowledge some of the members of the Department of Chemical and Environmental
Engineering for their unlimited help in the organization of the meeting. I am particularly grateful
to Julio Fernandez, who took care about the logistics of the meeting, to Prof. Jose Ramon Alvarez
for his help with the financial aspects and to Dr. Jose Manuel Benito, for his meticulous job of
compiling the abstracts and presentations, that ended up as this new report.
Jose Coca Prados
Professor of Chemical Engineering
Meeting host
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April 2002
WELCOME AND OPENING OF THE MEETING
The fourth annual meeting of the NATO/CCMS Pilot Study on Clean Products and Processes
was held on May 6-11, 2001 in Oviedo, Spain. The meeting was hosted by Professor Jose Coca
Prados, University of Oviedo, Department of Chemical and Environmental Engineering, Oviedo,
Spain. The meeting was held at the Oviedo Auditorium "Principe Felipe", near the city center and
old town. Oviedo, with a population of approximately 200,000, is located in the north of Spain, in
the central area of the Principality of Asturias. Oviedo is 227 meters above sea level with a
moderate climate with mild winters and cool summers.
This meeting includes delegates and participants from 21 nations. On Sunday, May 6, 2001, the
opening reception was held and delegates and participants were greeted by Professor Coca and
Dr. Subhas Sikdar, Pilot Study Director, U.S. Environmental Protection Agency, Office of
Research and Development, National Risk Management Research Laboratory, Cincinnati, Ohio.
Isabel Perez Espinosa greets Dr. Subhas Sikdar and Professor Jose Coca on behalf of
the Mayor of Oviedo, Spain.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
On Monday, May 7, 2001, the technical meeting began with an introduction from Dr. Sikdar,
introductions of national delegates and participants, and an overview of the meeting agenda, field
visits and events from Mr. Daniel Murray, Pilot Study Co-Director, U.S. Environmental
Protection Agency, Office of Research and Development, National Risk Management Research
Laboratory, Cincinnati, Ohio. The first of several special topic presentations was given by
Associate Professor Tillman Gerngross, Thayer School of Engineering, Dartmouth College,
Hanover, New Hampshire. His though provoking presentation was titled "How Green Are Green
Plastics?" In addition, several pilot project updates and "Tour de Table" presentations were given
addressing tools for pollution prevention (United States), hydrocarbon emissions from gasoline
blending (Portugal), integrated membrane operations (Italy), cleaner production strategies
(Ukraine), ceramic membranes (Russia), responsible industrial disposal (Spain), and cleaner
production information via the internet (Germany and United States). The day concluded with a
poster session and demonstrations of computer-based tools and information systems to support
cleaner production.
The technical meeting continued on Tuesday, May 8, 2001, with an overview of programs of the
U.S. National Science Foundation given by Mr. Thomas Chapman. The "Tour de Table"
presentations continued addressing pinch analysis of chemical processes (Slovenia), industrial
ecology (Norway), organizational factors affecting cleaner production (Hungary), reuse of
industrial dusts (Poland), industrial treatment with constructed wetlands (Portugal), agrifood
industry (Bulgaria and Greece), industrial water management (Denmark), pollution prevention
(Romania), and national cleaner production updates (Czech Republic, Israel, and Lithuania). Pilot
projects updates addressed using fewer natural resources and meeting peoples' needs (Moldova),
new processes and materials in the semiconductor manufacturing (United States and United
Kingdom), and implementation of cleaner production processes in member countries (United
States). The day concluded with two perspectives on university-industry cooperation from
Professor Coca (Spain) and Professor Jim Swindall, QUESTOR Centre, Queen's University,
Belfast, Northern Ireland (United Kingdom).
National delegates and meeting participants during the tour of Santa Maria delNaranco
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April 2002
The traditional field trip was held on Wednesday, May 9, 2001, and a special topic seminar was
held on Thursday, May 10, 2001. The seminar was titled "Environmental challenges in the
process industries". The seminar featured over a dozen local, regional, and national speakers
from Oviedo, Asturias, and Spain. The following technical presentations were given: Principality
of Asturias environmental policy; Advances in environmental aspects of desalination in the
Canary Islands; Environmental progress in Dow Chemical Iberica; Environmental policy and
energy consumption - a compromise solution; Lignosulphonates - environmental friendly
products from a waste stream; Hydrogen economy and fuel cells - energy for the future;
Membrane technology in the pulp and paper industry; Activities and initiatives to support
companies and business sectors to improve their relationship with the environment; Treatment of
oil-containing wastewaters using clean technologies; New national legislation on environmental
quality and clean production; Making carbochemistry compatible with the environment; and
Treatment of phenolic wastewaters in the salicylic acid manufacturing process.
Oviedo Auditorium "Principe Felipe "
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
TOUR DE TABLE PRESENTATIONS
PROGRESS AND NEW PERSPECTIVES ON INTEGRATED MEMBRANE
OPERATIONS FOR SUSTAINABLE INDUSTRIAL GROWTH
E. Drioli andM. Romano
Institute on Membranes and Modeling of Chemical Reactors. University of Calabria
ITALY
e.drioli@unical.it http://www.unical.it
Membrane science and technology has led to significant innovation in both processes and
products, particularly appropriate for sustainable industrial growth, over the past few decades.
The preparation of asymmetric cellulose acetate membranes in the early 1960s by Loeb and
Sourirajan is generally recognized as a pivotal moment for membrane technology. They
discovered an effective method for significantly increasing the permeation flux of polymeric
membranes without significant changes in selectivity, which made possible the use of membranes
in large-scale operations for desalting brackish water and seawater by reverse osmosis and for
various other molecular separations in different industrial areas. Today, reverse osmosis is a well-
recognized basic unit operation, together with ultrafiltration, cross-flow microfiltration, and
nanofiltration, all pressure-driven membrane processes. In 1999, the total capacity of reverse
osmosis (RO) desalination plants was more than 10 millions m3/day, which exceeds the amount
produced by the thermal method, and more than 250 000 m2 of ultrafiltration membranes were
installed for the treatment of whey and milk.
Composite polymeric membranes developed in the 1970s made the separation of components
from gas streams commercially feasible. Billions of cubic meters of pure gases are now produced
via selective permeation in polymeric membranes.
The combination of molecular separation with a chemical reaction, or membrane reactors, offers
important new opportunities for improving the production efficiency in biotechnology and in the
chemical industry. The availability of new high-temperature-resistant membranes and of new
membrane operations as membrane contactors offers an important tool for the design of
alternative production systems appropriate for sustainable growth.
The basic properties of membrane operations make them ideal for industrial production: they are
generally athermal and do not involve phase changes or chemical additives, they are simple in
concept and operation, they are modular and easy to scale-up, and they are low in energy
consumption with a potential for more rational utilization of raw materials and recovery and
reuse of byproducts. Membrane technologies, compared to those commonly used today, respond
efficiently to the requirements of so-called "process intensification", because they permit drastic
improvements in manufacturing and processing, substantially decreasing the equipment-
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
size/production-capacity ratio, energy consumption, and/or waste production and resulting in
cheaper, sustainable technical solutions.
The possibilities of redesigning innovative integrated membrane processes in various industrial
sectors characterized by low environmental impacts, low energy consumption, and high quality
of final products have been studied and in some cases realized industrially.
Interesting examples are in the dairy industry and in the pharmaceutical industry. Research
projects are in progress in the leather industry and in the agrofood industry based on the same
concept.
The continuous interest and growth of the various new industrial processes related to life
sciences, as evidenced also by the strategies and reorganization adopted by large chemical groups
worldwide in this area (e.g., Aventis, Novartis, Vivendi Water, etc.) will also require significant
contributions from membrane engineering.
FOSTERING RESOURCE EFFICIENCY THROUGH NETWORKING AND
CONVENIENT INFORMATION ACCESS - GERMANY'S
CLEARINGHOUSE COOPERATIVES ON CLEANER PRODUCTION IN
THE WORLD WIDE WEB
H. PohleaandK. Wessef
aFederal Environmental Agency (UBA)
GERMANY
horst.pohle@uba.de
bSonderabfall-Management-Gesellschaft Rheinland-Pfalz mbH (SAM)
GERMANY
pius@sam-rlp.de
The access to technology and management information is crucial for further implementation of
cleaner production processes in companies. With two new Internet gateways, Germany supports
this demand to foster sustainable development in industry. The German Federal Environmental
Agency (UBA) has established the first version of the website "www.cleaner-production.de".
Cleaner Production Germany (CPG) is a federal Internet information system for innovative
environmental technology and federal projects in Germany and a gateway to technology transfer
and contacts. The PIUS Internet Forum under www.pius-info.de is closely linked with CPG. It is
a cooperative web project of currently five German states with new partners to be acquired. The
large database of pollution prevention projects conducted in companies offers detailed
information about technology, experiences, costs and management. By extending the two
cooperating Internet platforms Germany wants to boost international environmental and
development cooperation and promote the transfer of environmental technologies.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
CLEANER PRODUCTION STRATEGY AND TACTICS
W. Zadorsky
Ukrainian Ecological Academy. Ukrainian State University of Chemical Engineering
UKRAINE
ecofond@ecofond.dp.ua http://www.zadorsky.8m.com
Cleaner Production is conceptual and procedural approach to production, demanding that all
phases of a product or process life cycle is addressed with the objective of preventing or
minimizing short- and long-term risks to the humans and the environment. Cleaner Production
utilizes improvements in product design, raw materials production, selection and their efficient
use, as well as production and assembly of final products, consumer use of the products, waste
and disposal recycling, transportation of raw materials and products, and energy savings.
Specifically, adoption of Cleaner Production principles offers industry opportunities to promote
operating efficiency while improving environmental performance. Source waste reduction
eliminates costly post-production effluent control or bolt-on treatment. This conserves raw
materials and energy, eliminates usage of toxic materials and reduces quantity and toxicity of all
emissions and wastes in a closed-cycle process. For products, Cleaner Production spans the entire
process life cycle from raw material procurement to disposal of byproducts of industrial material
processing. Cleaner Production is achieved by applying know-how, by improving technology and
changing attitudes. Cleaner Production is generally cost effective due to potential improvements
of both process efficiency and improved product quality. These economic advantages of CP are
especially evident when compared with other environmental protection strategies, for example
such as end-of-pipe wastewater treatment, waste processing, and exhaust gas treatment. Apart
from cleaner production in industry, it is possible also to survey opportunities and constraints for
cleaner energy conversion and improved energy utilization.
Recently, the main conception of nature protection in the Ukraine was the finding and analysis of
human impact on surroundings. Today the situation is changing and this defensive concept is
replaced by the new one, the main approach of which is the rebuilding of agricultural and
industrial complex. Significant Ukraine's problem is division economic, social and ecological
factors within the framework of systems of acceptance of the decisions at levels of a policy,
planning and management, that renders significant influence to realization of the concept of
sustainable development of the country and first of all - its industrial and agricultural production.
The Ukraine needs in environmentally sustainable economic and social development. It is
necessary for realization of all complex problems of the integrating of economic, biological and
human systems to collaborate between the engine-, info-, mathematical modeling- and eco-
communities. Development of sustainable development strategy is expedient, which had two
orientations: ecological safety and preservation of environmental natural environment, i.e.
development of sustainable social-ecological strategy with use of effective economic gears of
satisfaction of requirements of the person. The world experience testifies that the main tendencies
in maintenance of sustainable industrial development of an industrial region following
development of low- and non-waste technological processes and equipment and salvaging
industrial and household waste.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
The presentation first part is devoted to some results at cleaner production (CP) theory
elaboration and practice of CP theory use. CP strategy and tactics, based on systematic approach
to sustainable product development, is described. Main principles of the CP concept are as
follows:
All ecological problems should be solved in cooperation with a unified
comprehensive planning
Ecologizing economy supposes modernization of objects, which are real or potential
pollutants of environment
The prosperity of ecologizing implies existence of professionals skilled in the theory
and practice of ecologizing, cleaner production and ecological management
The creation of civilized ecological market is a necessary prerequisite for ecologizing
of economy and sustainable development of the country
As known, the CP concept as and sustainable development concept includes three aspects:
ecological, economic and social. Only mutually balanced simultaneous comprehensive tackling
of the three tasks (economical growth with simultaneous improvement of ecological conditions
and decision of social problems) will allow realizing progressive CP strategy. The system
analysis shows strong interaction and feedback among the mentioned three factors of CP strategy.
The set of engineering techniques and methods for Cleaner Production seems somewhat limited
and lacking diversity. Meanwhile there are a lot of effective methods to increase product
cleanliness. For example, we use the following Cleaner Production tools and methods:
Recirculating flow of the least hazardous agent taken in excess over its stoichiometric
value
Isolation (close-looping in structure) of flows of substance and energy by
recirculating, resulting to "idealization" of modes of synthesis and significant
reduction of speed of by- processes
Controlled heterogenization of the contacting phases for softer conditions and
improved selectivity
Separative reactions: removal of reaction products at the moment of their formation
from reaction zone, synthesis and dividing processes organizing in the same place and
in the same time), allowing to reduce formation of by-products by removal of a target
product from a reactionary zone at the moment of its formation
Synthesis in an aerosol to increase intraparticle pressure and reaction rate
Self-excited oscillation of reacting phase flows at frequencies and amplitudes
matching those at the rate-limiting tiers of the system
Flexibility and adaptability of technology and equipment allowing to ensure reliable
work of technical system by "internal" reserves (flexibility) of installation using, that
reduces an opportunity of harmful substances pollution or reception of a sub-standard
product
Minimization of time of processing and surplus less toxic reagent, resulting all to
increase of selectivity and reduction of formation of by-products
CP algorithm will look as a sequence of following actions:
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
1. DECOMPOSITION. Hierarchy level determination and technical system
decomposition. The analysis of the initial information including inspection of
industrial manufacture, with the purpose of its decomposition on typical levels of
hierarchy (for example, manufacture - plant item - installation -apparatus or machine
- contact device - molecular level).
2. IDENTIFICATION of an initial level. Revealing of the bottom level of hierarchy
limiting from the point of view of pollution to an environment. Definition of limiting
hierarchical level/levels. Herewith reasonable move on the hierarchical stairway from
top to bottom and use methods of expert evaluations.
3. SELECTIVITY & INTENSITY INCREASE. Increase of selectivity and intensity of
actually technological stages of processing at a limiting level of hierarchy. Choice of
CP methods depending on the limiting level scale (defining size) corresponding with
parameters of influence method to the system from the database.
The system approach that is demonstrated in the special table is connected tier of system with the
frequency order, dimension order, concepts and methodologies and with tools and methods for
Cleaner Production. There should be a match between a tier in a hierarchy and the methodology
of characterization, assessment or influence used at this tier.
Some tools and methods for CP are described:
Highest results we have when heterogenization is used as a part of Reactive Separation
Processes (RSP) ideology. It is discussed also number of possible mechanisms of
chemical reactions improving with increasing of their selectivity when mass transfer
process joints with chemical one in particularities at bubbles mode of phases interaction.
Parallel reactive separation processes (RSP) are using as Clean Reaction Technologies for
increasing a purity of production, Waste Reduction and for Pollution Prevention. Usually
reactive zone and distillation zone is the separate zone in similar units. But we will have a
lot of additional effects if these zones will be combined in joint volume. Then in the
reactive-separation zone not only the reaction heat will cause additional mass transfer
between vapor and liquid phases but also it will be increase a rate of the chemical process.
Laboratory and industrial research revealed that the reaction-separation mode is well-
suited for acylation, amidation, amination, condensation, cyclization, dehydration,
etherification, halogenation, hydrolysis, oxidation and other chemical reactions
Some of offered by the author of presentation ecologically friendly technological processes,
among which many are developed within the framework of CP program for working
manufactures, are submitted in the second presentation part as applied database "Commercialized
Technologies Virtual Market".
Third part of presentation is devoted to CP Problems in transition economy countries and to the
possibilities of collaboration in the frame of NATO/CCMS Program "Clean Technologies and
Products".
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
It's necessary to have for CP movement development worldwide: clear terms and definitions,
general theory, strategy and tactics for CP concept and manual for CP tools and methods,
compendium of the best CP practices, economic mechanisms of stimulating for the transition to
CP technologies, association, coordination and information of organizations and individuals are
dealing with CP. In the same time it is necessary to help the CP movement meet its goals in
transition economies as this countries have a lot of development features:
1. Methodology for application of CP philosophy to restructuring, military conversion,
privatization and economic transition at a national and regional levels.
2. Practicable program for embodying the CP concept under sweeping changes in the NIS
and other transition economies.
3. Restructuring, privatization and military conversion relationship to building an
environmentally friendly economy. It would suggest that new environmental and CP
challenges in transition economies be discussed.
4. Priority-based investment programs for and attracting investors to NIS.
New environmental and Cleaner Production challenges in transition economies must be included
in Cleaner Production concept realization. For example, there are severe environmental effects of
restructuring, military conversion, privatization and economic transition. In any case, transition
economies have no mechanisms for stimulating Cleaner Production technologies. It is desirable
to use the systems approach in Cleaner Production Concept Implementation (or Cleaner
Production Strategy and Tactics) for transition economies.
At the same time it is necessary to help Cleaner Production movement meet its economic goals in
transition economies which have development features as follows:
1. Methodology for application of CP philosophy to economic restructuring, military
conversion, privatization and economic in transition at a national or regional level.
2. Practicable program for embodying CP concept under sweeping changes in the NIS and
other transition economies. (May be it is desirable to launch a Special Pilot Project on
Systems Approach to CP Concept Implementation (or CP Strategy and Tactics) for
Transition Economies. In any case, transition economies have no mechanisms for
stimulating CP technologies).
3. CP oriented priority-based investment programs for attracting investors to NIS.
Cleaner Production main goal and objectives are:
1. Systematization of cleaner production general theory, strategy and tactics, search of the
tools and methods based on a systematic approach as a foundation of sustainable product
development.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
2. Searching and elaboration of the economic mechanisms stimulating transition to CP
technologies in conditions of transition economy.
3. Organizing of international collaboration, association, coordination and information of
organizations and individuals dealing with CP.
Besides we need the specific steps and tasks to be proposed:
Terms and definitions, unification of the terminology ofClean(er) Production
1. Writing and editing in Russian and English a handbook or practical manual of CP.
2. Organizing of an online CP Help and Consulting Service.
3. A compendium of the best CP practices at a pilot project of transportation environmental
problem realization for a large industrial city.
4. Launch a CP technology incubator or greenhouse.
Then we can receive some concrete results and expected outcomes:
1. A pilot project for demonstration of transportation environmental problem solving for a
large industrial city.
2. Handbook or practical manual of CP practices tools and methods.
3. Review to identify economic mechanisms stimulating transition to CP technologies in
conditions of transition economy.
4. Online CP Help and Consulting Service.
5. CP technology incubator (warm house).
Main directions our activities now are:
elaboration of strategy and tactics for cleaner production, waste management, pollution
prevention;
system ecologizing of acting manufactures;
development and introduction of methods of adaptation and rehabilitation of the
population in conditions of the increased technical loads;
development and realization of the program of sustainable development of industrial
region;
continuous ecological training and education, based on the concept of active constructive
ecology;
development of the information at cleaner production technology and equipment;
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
to demonstrate the economic benefits of pollution prevention and recycling to industry
business operations.
For the decision of problems of information exchange it is necessary realize the following
programs:
Creation of computer information base at ecological engineering and technologies of
cleaner production;
Issue a periodic regional ecological electronic newspapers, distributing ecological
information and experience of use of cleaner production in regions and in the world (with
use of networks);
Realization of active contacts to world community on exchange by the ecological
information;
Retraining of the experts of acting manufactures on directions resource saving and
ecological technologies.
It is necessary to give the main attention not so much to cleaning of gases and liquids as to many
non-waste technologies for processing of raw materials including but not limited to concurrent
reaction-dividing processes, new effective methods of recycling using capillary and porous
impregnation of waste materials, electric aerosol technology, and flexible chemical engineering.
And at last an important advantage in solving ecological problems is interdisciplinary approach
via experience of various experts from different organizations with the purpose of the best
decision making regarding specific problems.
There are some specific problems in the transition economies that need to be solved. For sample,
CP approaches are concerned not only with production but also with transportation. The traffic
has dramatically increased in Ukraine due to market development and occurrence of a great many
of trade intermediaries and small businesses. This resulted in aggravated negative influence of
transportation on environment, making cleaner transport a matter of survival and urging
immediate and competent decisions. The "free" market has displaced regular grades of petrol for
cheaper ones containing aromatics, that is hazardous byproducts of coke industry. These include
benzene, toluene, xylene and others and their combinations. Expert judgment is that these
aromatics cannot be burned in an engine completely and are massively discharged to air with
exhaust gas. No research into amounts of aromatics in exhaust has been conducted. The analyses
of government bodies generally do not include these compounds. Meanwhile, the content of
aromatics like benzene in a fuel is limited by standards of advanced countries. The above is not
limited to ecology of motor vehicles and is an issue with railway, water and air transport as well,
thus being a cross-disciplinary problem. Considering that there are a number of other
environmental issues common for all types of transport, a special discussing of scientists and
experts on various types of transport is necessary. The main topics are: ecology of vehicles,
environmental challenges of engines and fuel, environmental challenges of freight traffic,
passenger compartment ecology, ecology of accidents and emergency situations on transport,
environmental aspects of transportation infrastructure, environmental challenges of handling
cargoes.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Many countries in Europe have declared a shift from municipal waste incineration to other
technologies. May it is necessary to discuss results of environmental and economy analyses of
waste incineration and processing technologies. It is desirable to organize an Expert-online CP
Help or Consulting Service. May be it is possible to launch a CP technology incubator or
greenhouse.
It's reasonable to include in NATO/CCMS web site collaboration pages, for examples:
CP chat for Program participants,
Announcements,
Free consulting, expertise, audits,
Proposals and information about results of collaboration,
Virtual on-line TECHNOLOGICAL CP BUSINESS-INCUBATOR (VTBI-CP)
"INTELLECTUAL SERVICE". VTBI-CP will be a commercial NET.
We offer a wide program of mutually beneficial collaboration:
Joint scientific research, including participation in international scientific programs and
joint developments for industrial enterprises and other organizations
Transfer of new high technologies
Joint analysis of developments in science, industry, education and social policies in the
NIS countries
Joint research in permanent areas of applied chemistry, chemical processing and chemical
engineering, chemical industry, metallurgy, engineering, food-processing and
pharmaceutical industries
Exchange of leading scientists and specialists
Exchange of visiting professors that deliver lectures on the chosen themes
We hope collaboration will be useful and will help fulfill some domestic projects that bring
together industry, government, the scientific community and the public to attack challenges in our
community by using innovative solutions and appropriate international help.
CERAMIC MEMBRANES IN CLEAN PROCESSES IN RUSSIA
G. G. Kagramanov
Moscow Mendeleyev University of Chemical Technology of Russia
RUSSIA
kadri@muctr. edu.ru http ://www.muctr. edu.ru
The development of inorganic membranes in Russia began in early 40-s of XX-th century and the
main industrial application was the separation of gases. In the 80-s of the last century various
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
research groups and industrial enterprises were concentrated due to special program, financed by
government, for the development of ceramic membranes technology, production and realization
of membranes and units. Due to this program the technologies of micro-, ultra- and nanofiltration
ceramic membranes based on A^Cb, ZrC>2, TiO2, SiC>2, CeC>2, SiC were developed and various
processes and applications were studied. The first industrial output of ceramic microfiltration
membranes started in 1989 in Moscow region. The rate of ceramic membranes production in
Russia (100 m2 in 1989) reached 950 m2 in 1993 and 2 100 m2 in 2000. Basic industrial
applications, designs and technological data of ceramic membrane units for clean products and
processes in food industry (purification of wines, juices, vodka etc.), pure and waste waters
treatment, microbiological and pharmaceutical branches of industry (filtration of biomass, culture
broths etc.) are discussed.
TOWARDS RESPONSIBLE INDUSTRIAL DISPOSAL IN SPAIN
J. Coca
Department of Chemical & Environmental Engineering. University of Oviedo.
SPAIN
jcp@sauron.quimica.uniovi.es http://www.uniovi.es/~ingenieria.quimica
The international program Responsible Care was adopted by Spanish industries in 1993. In a
recent report [1] 76.4% of the Spanish companies are taking environmental measures to comply
with the legislation, and 64% in order to have a better public image. Since the Responsible Care
program was implemented, the annual average investment has been 9.300 M pts (58.1 Me ) and
18.000 Mpts (113 Me) were invested in 1999.
In 1998 there were 135 000 job positions in the area of environment, 30% involved with water
management and 29% with waste disposal. By the end of 2001 it is expected that the number of
jobs in the environment sector will be of 2000. For most companies environmental issues are the
fourth priority, after work safety and energy and materials savings. The larger investments on
environmental issues, and number of companies involved, in the industrial sectors has been: (oil
refining, plastics, energy plants) (93.1%), transportation equipment (85.3%), chemicals (83.3%)
and equipment manufacture (82%). The benefits of environmental investments are considered
low by companies, and only 41% of them admit some savings in product recovery or energy
savings.
Air pollution
The most important pollutants, which are usually measured as an indication of air-pollution are:
1. Solid particles (fine ashes, soot, etc.), 2. Sulphur oxides (SOx), 3. Carbon dioxide (CO2) 4.
Nitrogen oxides (NOx) and 5. Volatile organic compounds (VOC's). Air pollution is mainly
associated with energy production and consumption, but there are other sources such as
industries, agriculture, sprayers, dry cleaners, etc. In Fig.l the discharge evolution in Spain for
the aforementioned pollutants, since 1993, is shown.
10
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
The discharge decrease due to environmental actions, taken mainly by companies using
combustion processes, has been very important: 57% for solid particles, 24% for SOx, 40 % for
CC>2 and 43% for VOC's. However, there has been an increase in the absolute value for the NOx
emissions, as a result of the increasing number of cogeneration plants.
0.25
-ง O-2'
o, 0.15 -
2 o.i -
4000
3000
2000 ->>
VI
1000 ~
1993 1995 1997 1999
year
1-
0.5-
0
40000
30000 ฃ
20000^
O
10000 'S
0
1993 1995 1997 1999 2001
year
a. Solid particles (SP)
b. Sulphur oxides (802)
g 200 -
^ 15'
o 100-
o
oc 50-
0
5000
4000 j-j
3000 j~.
2000 g
1000S
0
1993 1995 1997 1999
year
c. Carbon dioxide (CO2)
0.8 -
M
0.4 H
0
25000
20000 ^
15000 >-,
- 10000 O
5000 ~
0
1993 1995 1997 1999
year
d. Nitrogen oxides (NOx)
> 0.4-
j? 0.2
0
15000
14000
13000
- 12000
11000
1993 1995 1997 1999
year
e. VOC's
Figure 1. Evolution of air emissions in Spain since Responsible Care program was established
11
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
Water pollution
Most of the industrial processes are designed either to recycle or save water. It is considered that
most of the industrial water once it has been used returns to the life cycle (80-90%). The
evolution of some important industrial wastewater characteristics is shown in Fig.2. They
correspond to effluents from manufacturing and refrigeration processes.
60
30 -
20 -
800
600
- 400 ^
(
h
- 200 '
0
0.6
1993 1995 1997 1999
year
a. Heavy metal (HM)
g 0.5 -
"o 0.4-
OH
4; 0.3 -
CM
H 0.2-
00
* 0.1 -I
0
10000
8000
6000
4000
2000
0
1993 1995 1997 1999
year
b. Total phosphorous (TP)
0.5
0.4-
0.3
0.2-
6000
- 5000
4000
3000
- 2000
1000
0
2.5
1993
1995 1997
year
1999
c. Total nitrogen (TN)
2 -
1.5 -
Q . ,
o i H
o
op 0.5 -
0
30000
25000 ^
20000 ^
15000g
100000
5000
0
1993 1995 1997 1999 2001
year
d. Chemical oxygen demand (COD)
Figure 2. Evolution of wastewater parameters in Spain since Responsible Care program was
established
The total discharge of pollutants has decreased by 74% since 1993. The substantial decrease in
the heavy metals contents is likely due to the reduction of mercury in effluents from the chlorine-
alkali industry. The reduction of phosphorus content since 1997 is due to a more effective
effluent treatment and the implementation of clean technologies by some companies. The
reduction in the remaining parameters has been: 59% for nitrogen and 70% for COD.
Solid wastes
Industrial solid wastes have a wide physical and chemical nature. They may be hauled in private
dumps, disposed of by landfilling and burnt in the plant or in an outside incinerator, if no toxic
12
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
substances are released. Industrial solid wastes have increased since 1993, but have decreased by
36.8% per ton of product, Fig. 3a. A new law was passed in 1997, to comply with the
Responsible Care program, and Fig. 3b shows the evolution of dangerous solid wastes.
25
6 20 H
ft 15
I10
0
500000
- 400000
03
300000 jฃ,
200000 vi
KH
100000 ~
0
1993 1995 1997 1999
year
a. Industrial solid wastes (ISW)
CO
tn
4 -
2
0
4000
3000
- 2000 >
t
>
1000 '
0
1993 1995 1997 1999 2001
year
b. Hazardous solid wastes (HSW)
Figure 3. Evolution of solid wastes in Spain since Responsible Care program was established
Membrane processes for cleaner production
1. Pulp and paper effluents treatment
The actual concern about water pollution from industry has moved most of the countries to
increase restrictions over effluent disposal. Pulp and paper industry is particularly affected
because of its water requirements.
Removal of pitch by microfiltration (MF). The use of MF to remove pitch form different
streams in the pulp production process can lead to an increase of pulp quality as well as the
reduction of some problems associated to the accumulation of such matter in the process.
Effluents from process waters were fed to a MF pilot plant at a temperature of 70-80 ฐC.
Pressures up to 5 bar were applied. Complete removal of pitch (98-100 %) was achieved at all
tested conditions. Feed velocity was found to have a very important effect on flux.
ECF bleaching effluents treatment. Bleaching stages in the pulp and paper industry are
responsible for more than 50% of water pollution. Conventional treatments reduce BOD and
COD, but they are not effective regarding colour reduction. In this project different
commercial tubular ultrafiltration and nanofiltration membranes are used for the treatment of
several effluents from the bleaching plant of kraft pulp. The research has been focused on
determining the feasibility of the process in order to utilize it in industrial scale. Results show
that nanofiltration is a reliable technique for the treatment of the bleaching effluents and their
reuse in the bleach plant.
TCP bleaching effluents treatment. The use of nanofiltration membranes allows the removal
of low molecular weight matter (around 500 dalton) as well as di- and tri-valent ions. In the
13
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
present case, transition metals such as iron and manganese have been removed not in the
ionic form in solution, but as a chelate formed with an acetic acid-based chelation agent.
Kraft black liquor fractionation. The most common use of kraft black liquors is as an energy
source, being burnt after concentration, in order to produce steam and recover chemicals
which are recycled to the process. An alternative process for overflows and spillages might be
the recovery of lignin and further use of the fractions, in the manufacture of more valuable
compounds. Membrane processes are effective in the separation of lignin fractions and also
allow the recovery of salts, that in turn could be recycled to the pulping process. Experiments
were carried out in a tubular membrane module, using ultrafiltration membranes. Diafiltration
experiments have been also carried out to enrich the retentate in the high molecular weight
fraction.
2. Removal of waste emulsified cutting oils
Oil refining and metal-finishing industries, such as rolling mills and mechanical workshops,
produce large quantities of oily wastewaters that need to be treated before their disposal. The aim
of this project is the design and construction of a modular pilot plant for the treatment of different
water-based coolants and oily wastewaters generated in metalworking processes and steel cold
rolling operations. Different treatments can be carried out depending on the nature of the oily
waste emulsion, such as coagulation/flocculation, centrifugation, membrane processes (micro and
ultrafiltration) and sorption processes.
The effect of surfactants present in the feed emulsions, is being also be studied, due to their
considerable amount present in permeates, yielding an effluent with a high organic content.
Furthermore, the formulation of new water-based cutting fluids for their use in metalworking
processes and steel cold rolling operations, which could be reused and/or removed by means of
clean and environmental-friendly technologies, will be carried out.
3. Membrane-based hybrid processes
Phenol removal by pertraction. The removal of phenolic compounds from waste streams is
very important since phenol is present in aqueous effluents from several industries (i.e.,
petrochemical, pulp and paper, polymer and pharmaceutical). Phenol removal has been
carried out by pertraction, a process involving solvent extraction using hollow fiber modules.
The limitations of the conventional two-phase separation equipment, such formation of stable
emulsions, loading requirements and flooding restrictions can be overcome using a hollow
fiber membrane contactor. The organic phase flows on the shell side while the aqueous phase
is pumped through the fibers lumen. The study is focused on the influence of hydrodynamics
the aqueous and organic phases on the overall mass transfer coefficient. Continuous
extract!on-backextraction experiments, using two modules to respectively load and regenerate
the organic phase, are being carried out.
Enzymatic membrane reactors for the production of lactic acid esters. The aim of this work is
the valorization of whey permeate by means of the production of lactic acid and valuable
14
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
derivatives, such as lactic acid esters. For that purpose, three tasks are being carried out: i.
Improvement of the continuous production of lactic acid by fermentation by means of lactose
prehydrolysis. ii. Recovery of lactic acid from broth by membrane-assisted extraction
(pertraction). iii. Production of lactic acid esters by combined reaction-separation processes.
In order to carry out tasks i and iii, two systems involving enzymatic membrane reactors have
been constructed. Once the lactic acid is recovered and purified from the fermentation broth,
it can be used as raw material in the production of a number of valuable chemicals, i.e., esters
(which then can be used as solvents from renewable resources, or as intermediate products in
the manufacture of, e.g., biodegradable polymers). The esterification reaction is usually
carried out in a reactive distillation column, catalyzed by either mineral acids or ion-exchange
resins. This reaction could also take place in an enzymatic membrane reactor in organic
phase, by immobilizing a lipase capable of catalyzing the conversion.
4. Removal of volatile organic compounds (VOC's) by pervaporation
The purpose of this work is to optimize the operating performance of a pervaporation process for
the removal of VOC's from aqueous streams. Toluene-water and trichlorethylene-water systems
have been studied using a polydimethylsiloxane membrane.Feed composition has been varied
from toluene and trichl or ethyl ene solubilities down to 100 ppm.
Catalytic treatment of volatile emissions from coke ovens
Coke ovens are a major source of atmospheric pollution. Their emissions are rich in methane (up
to 12000 ppm), different VOC's (such as benzene or ethylene), ammonia, hydrogen sulphide, and
sulfur and nitrogen oxides. The abatement of VOC's and CH4 in these emissions is especially
difficult, because of the presence of the above-mentioned inorganic compounds.
The scope of this project is the selection of catalysts to carry out the catalytic incineration of
these emissions to work in this environment. The main conclusion of these experiments were the
higher activity of Pd catalysts (although their resistance to poisoning is not very high) and the
predominant role of the sulphur compounds in the deactivation of the catalyst.
References
Fundacion Entorno, "Informe 2001 de la Gestion Medioambiental en la Empresa Espafiola"
(2001)
Compromiso de Progreso de la Industria Quimica Espafiola. Seguridad, Salud y Medio Ambiente
(1999)
15
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
CLEANER CHEMICAL PROCESSES BY USING PINCH ANALYSIS AND
MATHEMATICAL PROGRAMMING
P. Glavic
Faculty of Chemistry and Chemical Engineering. University of Maribor
SLOVENIA
gl avi c@uni -mb. si http ://atom. uni -mb. si
Energy and material recycling is required to save the natural resources and protect the nature.
Pinch analysis is nowadays a practical tool for designing heat exchanger networks (HEN) in
chemical and process industries. Yet, heat integration alone is not sufficient for process
integration. The largest savings are achieved when simultaneously integrating and optimizing
heat and mass flows. Mathematical programming is increasingly used to optimize process
structure and its parameters, both in continuous and batch operations. Two examples of the
cleaner production program in Slovenia will be shown:
Sulfuric acid production from sulfur has been optimized simultaneously using rigorous models
and direct search optimization. The additional profit may be increased by 2.8 MEUR/a, mainly
because of higher temperature driving forces yielding a reduced investment in HEN. The profit
comes mostly from the 13.3 MW increased steam production without using any fuel!
*TF
Figure 1. Flowsheet of the modified sulfuric acid process
16
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
An existing, low pressure Lurgi methanol process was to be retrofitted and optimized. A three-
step approach was applied:
Generation of a superstructure by pinch analysis
Formulation of a mathematical model
Optimization using process simulator and mathematical programming
Simultaneous optimization of heat, conversion and mass flow rates has saved 5.26 MEUR/a, i.e.
6.7 % of the total annual income, with the payback time of less than 1 month. 97 % of the savings
come from the additional methanol production. 2.4 MW of additional steam can be produced
using 0.5 MW of additional fuel only and 17 % of cooling water is saved.
(Hal
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Figure 2. Methanol process flowsheet after heat integration
17
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
POLLUTION PREVENTION IN ROMANIA - OPTIMISTIC
PERSPECTIVE
V. Harceag
FBCR-Maunsell
ROMANIA
viorelH@k.ro
As many other East European countries, Romania is crossing a difficult transition period. In
political terms, it means passing from communist political system to the democratic one, and in
economical terms from a strong centralized to the free market economy. In the first years of
transition, many industrial plants in Romania strongly diminished their production, this reduction
ranging from 30 up to 80 %. After a long period of stagnation at this very low level of
production, the surviving plants will increase (most of them slowly) their production in the next
years. Like other East European countries, Romania has to help its viable industrial plants to
increase their production, or it will remain longer as undeveloped country.
IMH^lKtAL
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Figure 1. LCA scheme (A) and pollution prevention (B) for an industrial process
r
New equipment.*
AmastBtnt l
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The
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Figure 2. LCA scheme for pollution prevention
18
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
From ecological point of view, the reduction of industrial production level lead to smaller number
of pollution sources and smaller quantities of emitted pollutants. The transition period has
represented for environment in Romanian a break in its fight with industrial pollution. This truce
will be ended soon, and the only help for environment will remain pollution prevention (P 2). A
Life Cycle Assessment scheme for any industrial plant reveal that pollution prevention measures
applied in the plant will lead at reduction of pollutants emissions, and also to some saved money.
Optimistic perspective of pollution prevention in Romania is derived by the fact that it is the only
way for industrial development and Romania can not remain an undeveloped country. The paper
presents some individual actions for P 2 application in Romanian industry.
CLEANER TECHNOLOGIES AND INDUSTRIAL ECOLOGY
A. M. Fet
Norwegian University of Science and Technology
NORWAY
Annik.Fet(3)iot.ntnu.no www.iot.ntnu.no/~fet
The presentation will give an overview of research projects within the area of Industrial Ecology
and Cleaner Production at the Norwegian University of Science and Technology, NTNU. UNEP
has defined Cleaner Production as "the continuous application of an integrated preventive
environmental strategy applied to processes, products and services to increase eco-efficiency and
reduce risks to humans and the environment." In the presentation I will exemplify this by case-
studies from Norwegian industry.
World Cleaner Production Society (WCPS) is a Norwegian based group of consultants working
in a number of countries on CP programs mostly funded by NORAD and the Norwegian Ministry
of Foreign Affairs. The presentation will give an overview of such programs and how they are
performed in different countries all over the world. Our first CP program was initiated in Poland
from 1990, and later on other CEE countries. Based on experiences from Poland, Czech and
Slovak Republic, a guide on implementation of CP was developed ("The Best Practices Guide for
Cleaner Production Programs in Central and Eastern Europe"). The approach is very practical
with applying principles like in plant training, training by doing and train the trainers. Later on
CP Programs have been implemented according to the "Best Practices Guide" in north west
Russia, Lithuania, Tunisia, Zambia, Indonesia, China (Beijing and Hunan). For the time being
programs are running in Russia, Tanzania and Pakistan. Some experiences and results form these
programs will be presented.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
WCPS * CP program (The Norwegian Model)
VV* I.
Plenary session I (4 days!
Project work in companies
I Company visit I by CP- Consultant
B Plenary session 11(J days)
s weeks ^^^^^B Projetl work in companies
M-ii II
Plenary session III (3 days!
5-8 weeks
Project work in companies
i weeks -^M Exam {1
Toia] 5 * 7 mouths
THE ROLE OF ORGANISATIONAL FACTORS IN THE
IMPLEMENTATION OF CLEANER PRODUCTION MEASURES
G. Zilahy
Cleaner Production Centre. University of Economic Sciences and Public Administration
HUNGARY
zilahy@enviro.bke.hu http://hcpc.bke.hu
An empirical research undertaken at the Hungarian Cleaner Production Center at the Budapest
University of Economic Sciences concentrated on the organizational factors of energy related
cleaner production measures at several significant Hungarian companies. The underlying
objective of the research was to analyze this special set of barriers to preventive environmental
actions which often impede the implementation of cost effective instruments at the company
level. As a result of the research, a number of these organizational barriers have been identified at
eight enterprises of the Hungarian industry and recommendations have been developed to
overcome such difficulties.
The international literature concerning the improvement potential of existing energy efficiency
levels refers to the so called "energy efficiency gap" as the energy efficiency potential which is
not exploited in practice and indicates the difference between the economically optimal and
practically implemented levels of energy efficiency measures. In other words, the energy
20
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
efficiency gap covers the total amount of so called "no-regret options" (options which are
feasible to implement purely on a financial basis) which are not utilised by individual producers
or by state organizations.
Several reasons for the existence of the energy efficiency gap have been identified during the last
decade which focus on the following question: why does the practical implementation of energy
efficiency measures lag far behind potential energy efficiency levels suggested by both
theoretical results and implemented practical solutions (for a detailed discussion on the energy
efficiency gap see for example the special edition of Energy Policy [1]).
Similar questions have been the focal points of discussions between cleaner production experts at
the national and international levels during the last couple of years: why are cleaner production
measures not implemented on a much wider scale and why is it so hard to convince company
representatives of the advantages of preventive environmental measures.
Different explanations have been developed to answer these questions concentrating on market
barriers, the risk and uncertainty of preventive environmental actions and - lately - some attention
has been paid to the organizational factors determining the level of preventive environmental
measures (see for example [2] and [3]).
For the purposes of this study organizational factors will be defined as those factors characteristic
to an individual enterprise which have an influence on the level of its preventive environmental
actions. Organizational factors include the size, organizational form and industry of a company,
the available infrastructure (the state and type of equipment used), and human behavioral
patterns, etc.
The presentation will focus on the organizational factors of preventive environmental measures
specific to a set of eight leading Hungarian companies. Results prove that the implementation of
such measures requires far more than the availability of financial resources and the identification
of cleaner production options, but one should not forget about the built-in capital already used
and other infrastructural barriers; the motivation and commitment of employees at all levels of
the organization; the process of decision making within the organization; organizational learning
and issues relating to organizational culture.
References
[1] Energy Policy, Volume 22, Number 10
[2] DeCanio SJ. The efficiency paradox: bureaucratic and organisational barriers to profitable
energy saving investments, in: Energy Policy, Volume 26, Number 5, 1998
[3] Lutzenhiser L. Innovation and organizational networks - Barriers to energy efficiency in the
US housing industry, Energy Policy, Vol. 22, No. 10, 1994
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
NATIONAL PROGRAM FOR CLEANER PRODUCTION
D. Sucharovova
Ministry of the Environment
CZECH REPUBLIC
Sucharovova_dagmar@env. cz
The preventive strategy for environment conservation assessing the impacts of man onto the
environment as a whole - in an integrated manner - and does not support pollution transferring
from one component of environment into another one, provides options for choosing method for
achieving the set goals in the environment protection with the use of preventive methods. Cleaner
production is one of the instruments supporting application of preventive protection of the
environment and contributes to sustainable development in the Czech Republic.
The worldwide tendency in environment conservation aiming at the use of preventive instruments
in protection of the environment, many a time confirmed high efficiency of the cleaner
production method for industrial plants and services, these were the main reasons why the Czech
government approved in its decree no. 165 of Feb 9, 2000 the National Program of Cleaner
Production to support such activities and greater exercising thereof in all branches of the national
economy. First information assessing the benefits of cleaner production method were submitted
to the government in March 2001 and adopted by the government in April 2001.
In the course of cleaner production implementation in the CR, several very positive results of this
method were achieved in the environmental effectiveness terms which took effect e.g. in decrease
in the amount and toxicity of waste (solid, liquid and gaseous) directly with their sources, more
effective use of energies, raw materials and materials was achieved resulting in savings with the
plants. This confirmed the economic benefits of this method.
Application of such method led many times to decrease in capacity of the end technologies
(waste treatment plants, separators and other devices limiting the pollution output into the
environment); in some cases the cleaner production even caused that installation of such end
technologies was unnecessary. This method concerns also the company management and
organization where saving of labor was noticed several times.
Introduction of cleaner production in companies led simultaneously to continuous decrease in
adverse impacts of production onto the environment. Undoubtedly, another important aspect is
that the introduction of cleaner production decreases not only the impacts onto the environment,
but also on human health and safety.
Based on its achievements in enforcing and implementation of cleaner production within the
National Program for Cleaner Production, the Czech Republic was rated positively at the 6*
worldwide seminar on cleaner production organized by UNEP and Canadian government in
Montreal in 2000. Based on an agreement between the Minister of Environment of the CR, Mr.
Kuzvart, and the undersecretary of the UN and the executive director of the UNEP, Mr. Klaus
22
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Topfer, the 7th seminary on cleaner production will take place under the auspices of UNEP in
Praha in 2002.
CYCLE OF REUSING INDUSTRIAL DUSTS FOR WASTEWATER
TREATMENT AND CONSTRUCTION
A. Doniec
Pollution Prevention Center. Technical University of Lodz
POLAND
andoniec@ck-sg.p.lodz.pl http://www.p- lodz.pl
Among the pollutants which are released into the natural environment there are chemical
compounds containing heavy metals. A variety of physico-chemical techniques are employed for
removal of heavy metals from industrial wastewater. Among these techniques, adsorption and ion
exchange methods are granted a particular interest. One of them is based on the utilization of
waste industrial dusts.
Fly ash produced by coal-fired power plants is utilized as a raw material for the production of
foamed cellular concrete blocks (autoclaved aerated concrete) using the foam-gas-silicate
technology (FGS). The metal processing industry produces a large amount of iron containing
dusts. An appropriate composition of the concrete mixture and the iron rich dust may produce a
highly efficient material which can uptake heavy metals from industrial wastewater.
The Pollution Prevention Center at the Technical University of Lodz has developed an adsorbent-
like material which is a type of cellular concrete with built-in active centers. The adsorbent is
made of waste materials, thereby it is cheap. The effectiveness of the material work is very high.
After a relatively short time, 90 % of metal is removed from the standard aqueous solution of a
salt of a single metal. The usefulness of the material has been corroborated during treatment
process of wastewater created in electroplating facility. In the cleaning process, the treated stream
goes through a layer of the material (fixed bed) placed in a cylindrical apparatus. The bed of 1 m3
volume has an ability to uptake 25 to 50 kg of metal from a solution, which means cleaning
capacity ranging from 2.5 to 5 x 103 m3 of waste water containing 10 mg/m3 of metals. The heavy
metals comprised in the material after being used up are no longer in ionic form. The form of the
trapped metals is resistant to being washed away from the concrete matrix, thus the exploited
adsorbent may be used again as an aggregate for production of lightweight building blocks (non-
fines concrete) or in other construction materials.
23
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
CASE STUDIES OF INDUSTRIAL WASTEWATER TREATMENT IN
CONSTRUCTED WETLANDS
S. Martins Bias
IST/Centre of Biological and Chemical Engineering
PORTUGAL
susetedias@ist.utl.pt http://dequim.ist.utl.pt
Potential of constructed wetlands systems for the treatment of industrial wastewater will be
presented.
Constructed wetlands combine the benefit of an aerobic biological filter with the physico-
chemical properties of the soil matrix and of the vegetation ryzosphere due, mostly, to the large
dynamic surface area that it supplies to the adhesion of microorganisms enabling oxygen and
nutrients transfer.
Helophytes such as Phragmites sp., common reed, is one of the most abundant plant in the
Portuguese river banks being the one selected for all the cases shown.
Reed beds have been built and operated since 94 at large industrial scale aiming the removal of
nitroaromatic compounds and of large quantities of nitrates. A sandy-clay vertical and a light
expanded clay aggregates horizontal, subsurface flow systems were used for organics and
inorganics removal, respectively. The high removal efficiency obtained in each case enables the
possibility of the recirculation of the treated water to the process.
Landfill leachate and wastewater from the MSW transfer station is also being treated in a closed
reed bed system, except for very high rainfall situations, with success.
Agroindustrial effluents namely those with a very high impact in all the Mediterranean region,
like olive mill wastewater are being applied to reed beds which eliminates the toxicity associated
with polyphenolic compounds and simultaneously reduces the organic matter content.
Design strategy from laboratory scale to full scale will be discussed.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
CLEANER PRODUCTION AND PRODUCTS IN LITHUANIA
J. Staniskis
Institute of Environmental Engineering (APINI)
LITHUANIA
Jurgis. Staniskis@apini.ktu.Lt http ://www.ktu.lt/apini
We have to agree, that Cleaner Production (CP) should attack the possibilities for making
improvements in use of energy, the use of raw materials, the reuse or recycling of waste energy
and materials. CP has several clear advantages over pollution control. Any pollutant that reaches
the end of the pipe represents a loss of raw material Since CP seeks to minimize the amount of
material that suffers this fate, it is good way of conserving natural resources.
At the same time there are also difficulties inherent in the cleaner production concept. From the
perspective of the authorities, it is far more problematic to legislate and monitor than
conventional pollution control. CP is not usually accomplished simply by placing a new
equipment immediately ahead of a discharge point. Identifying good CP solutions often requires
a high degree of technical expertise and creativity, and ideas are not always directly transferable,
even between similar industrial facilities.
When looking to international literature on case studies for the implementation of CP in industry,
there is an overwhelming number of good housekeeping examples reported. Sometimes one gets
the impression that CP in practice is mostly good housekeeping oriented. This is, however
according our experience not the case, but in its beginning CP naturally tends to focus on the
easiest achievable option-'picking the lowest hanging fruits"
Normally, good results were achieved by use of conventional mass balances for energy and given
materials. Mass balances should be performed in practice much more than they are today, both to
have an idea of sources and losses in daily operation of the production processes, and particularly
before larger investments are introduced. Mass balance equations together with objective
function, limitations, initial and final conditions can serve for the advanced process control and
process optimization.
Cleaner production approach depends on overall process designs that are intrinsically
environmentally friendly. This calls for the philosophy of process design that recognizes the unity
of the whole process called as process integration. A systematic approach to industrial process
designs fundamentally changing the way in which process design and retrofit activities are
carried out. This method do not, in general, attempt to invent new types of equipment or unit
operations, rather, they focus on ensuring that existing process technologies are selected and
interconnected in the most effective ways. Typically the procedures start with an overview of the
process as a whole, rather than focusing on individual unit operations or pieces of equipment. In
this way an optimal structure can be developed for the overall plant, with individual items of
equipment being fit into this structure.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
According the original UNEP definition Cleaner Production is the conceptual and procedural
approach to production that demands that all phases of the life cycle of a product or of a process
should be addressed with the objective of prevention or the minimization of short and long term
risks to humans and the environment. Cleaner Production processes means activities aiming to
improve the CP aspects of production process design and operation. Such measures normally
include operational changes and technical improvements in (parts of) the industrial production
process, in order to achieve waste prevention or minimization, or the reduction of energy and raw
materials input. In practice, very many such initiatives aim to close the production loops of a
process, which often may be the first step to achieve waste minimization.
Cleaner Production Product means activities to improve the environmental qualities of products,
based on life cycle or "cradle-to-grave" approach. Such measures usually involve environmental
impact assessment in the life cycle oriented production, use and final destruction of the products
including their input components.
General findings and considerations:
Industry still does not consider Cleaner Production initiatives as an option for improving
productivity parallel to an increased protection of the environment. End-of-pipe solution
is commonly applied if environmental demands are to be met by converting pollution
from one form to the another
Investments in Cleaner Production increase the profitability for industry by increasing
productivity and product quality, cutting the cost for raw materials and energy, reducing
the need for large investments in pollution abatement equipment
It is important to integrate Cleaner Production efforts and general development and
innovation issues. NGOs, motivated industrial sectors and labor unions must be more
involved in the discussions about the outcome and objectives for Cleaner Production,
and the principles in the national legislation could be launched in order to promote
Cleaner Production including more strict standards
There is an urgent need to integrate Cleaner Production into EMS. Firstly, Cleaner
Production is not a continual and normal practice for industry. Secondly, Environmental
Management Systems are no guarantee that Cleaner Production will be applied or even
an environmental performance above regulatory requirements will be obtained. EMS
focuses on quality and strengths of procedures, and not the actual outcome of these
procedures regarding pollution abatement and improved resource productivity
Environmental reporting and data in management context could be as an opportunity to
promote environmental improvements and cleaner production. Data logging in
Production Management Information Systems to control budget compliance could
embrace the logging of essential environmental data to control environmental targets. A
link between management accounting and environmental management could be created
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April 2002
based on key performance indicators, that encompass environmental targets, such as
decrease in outlets, degree of compliance, and number of spillage
Cleaner Production requires the involvement and support of managers and workers at all levels
within the organization. Integrated, preventative environmental options have to be based on the
motivation of such people, which is a key reason for a shift towards consensus-seeking regulation
strategies. Therefore, extremely important for the successful CP implementation is an integration
of technical, managerial and financial means and possibilities. The growing acceptance of new
terms like "sustainable industries" and "industrial ecology" indicates that one is looking in the
right direction.
As it was mentioned before, system's approach should be used to cleaner production assessment.
In order to be able to identify waste prevention activities, the field of interest has to be defined as
clearly as possible and a method has to be used which is likely to produce the desired answers to
the question.
Professor Jurgis Staniskis, APINI, Kaunas University of Technology, giving a presentation on
Cleaner Production and Products in Lithuania
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
CEVI, THE DANISH CENTRE FOR INDUSTRIAL WATER
MANAGEMENT
H. Wenzel
Technical University of Denmark
DENMARK
wenzel@ipt.dtu.dk www.cevi.org
Running now on its third year, the center has progressed on both method development and
Cleaner Production implementation in industry. This pilot project up-date will report the progress
within textile industry, moulded paper pulp industry and industrial laundering as well as within
method development.
Textile industry. A number of process modifications were identified within the polyester yarn
dyehouse among which were substantial reductions on resource consumption and effluents from
CIP (Cleaning-in-Place) processes. A liquor displacement insert (a so-called "dummy") for use
during the frequent CIP of the dyeing machines was developed and implemented successfully
reducing water, energy and chemical consumption and emission by more than 50%. Moreover, a
spray rinse system for CIP'ing the chemical-addition tanks was developed and implemented
leading to even greater relative savings. Both systems have simple pay-back periods of a few
months. Energy and mass integration studies were carried out identifying large potentials for heat
exchange and direct water recycle - up to around 50% savings. The direct water recycle options
were successfully tested in lab-scale and subsequently in full scale for several weeks
documenting the potentials. The feasibility of counter current evaporation and membrane
technology was investigated for upgrading the remaining water for reuse. Membrane technology
was found to be the most promising alternative, and both nano-filtration and reverse osmosis
were tested in lab-scale and pilot scale. At present, large pilot scale tests are conducted and some
problems with pre-filtration of various suspended solids are experienced.
Textile laundering. Successful operation of full scale direct reuse of around 40% of the water
has been achieved at a batch workwear laundry over a year. Moreover, biological treatment of the
remaining water has been established and operated documenting that its is possible to up-grade
and reuse the water in the wash process by this technique. The hygienic quality of the water most
be controlled and further improved, though. Ultra-filtration of the wash water was tested in pilot
scale showing good performance of the ultra-filtration, but problems with reusing the permeate in
recipes comprising wash of slaughterhouse textiles, probably due to presence and/or formation of
volatile fatty acids lowering the alkalinity of the permeate unacceptably. Membrane Bio-Reactor
(MBR) technology was successfully tested in pilot scale, and full scale implementation is being
considered for further testing at one laundry.
Moulded paper pulp industry. A number of water recycle scenarios were simulated by
computer modeling and by lab-scale construction and simulation of the systems. The water
quality of the systems in the various scenarios was thereby simulated and tested, identifying thus
the physical, chemical and biological quality of the recycled water in the scenarios, including the
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growth potential for microbial growth. It was found that the easily degradable organic matter was
released from the raw material immediately after pulping. Moreover, it was found that a
substantial part of the degradable organic matter was added via the ancillary substances. Nitrogen
has proven to be limiting to growth, and nitrogen is added partly with the raw material partly with
chemicals, mainly with the biocides. It seems, thus, that the biocides to some extent carry within
them the cause of the need for them. Alternatives to using biocides, i.e. using dispersing agents to
prevent the formation of biofilm on the inner walls of the system, was successfully tested in full
scale. Moreover, it turned out that emptying and cleaning the system every two weeks is enough
to prevent growth, and that such a system can be operated with no use of biocides what-so-ever.
Method development. In a US-Danish co-operation, simple and operational methods for process
integration were developed applicable for both batch and continuous processes. The methods
have been prepared and submitted for publication in Journal of Clean Products and Processes.
Various softwares for computer modeling and simulation are under investigation and testing. A
technology database is under preparation.
Newsletter. The progress and results achieved in the center is briefly reported in a newsletter
available on the center web-site: www.cevi.org.
AGRIFOOD INDUSTRY IN BULGARIA
S. Tepavitcharova
Institute of General and Inorganic Chemistry, Bulgarian Academy of Sciences
BULGARY
stepav@svr.igic.bas.bg
The development of cleaner food production industry in Bulgaria is a part of the National Action
Plan on the Environment - Health. By this Action Plan Bulgaria integrates to the policy and
actions of the European Union for strengthening human health and sustainable development of
the countries.
The Bulgarian legislative and sub-legislative framework related to the safety food is in a process
of harmonization with the EU Directives, recommendations of the Food Code standards, and ISO
systems. Actualized Rules on hygiene requirements to the food additives have been adopted and
they are approximated to the EU directives in this field. Act on Foods had been adopted in 1999.
Programs are developing in different regions of the country for introducing the EU hygiene
standards and requirements on the food processing and reprocessing.
The measures mentioned above give us a possibility for development of the food industry at a
European level. Food and food processing policy is a part of the National Agricultural policy.
Among the agricultural priorities the following concern food and food processing:
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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Improvement of the national legislative framework in the field of safety food and its
harmonisation with the EU legislation. This includes development of acts, legislative
norms and standards;
Strengthening and improving monitoring system on food control. This includes control on
food agricultural products, their processing and sell; monitoring on food safety.
The training priority in the Action plan is to provide conditions for training high-quality
specialists in the field of environment - health, able to ensure its effective management and
optimization.
Dr. Stefka Tepavitcharova, Bulgarian Academy of Sciences
THE STATE OF PLAY OF THE IPPC/96/61/EC DIRECTIVE: THE CASE
OF FOOD INDUSTRIES WITH SPECIAL REFERENCE TO GREECE
G.P. Gallios, M. Tsimidou and I. Panagopoulos
Aristotle University of Thessaloniki. School of Chemistry
GREECE
gallios@chem.auth.gr http://www.chem.auth.gr
Even though, the last decades significant improvements have been achieved in industry regarding
several major polluting substances, industrial production processes still account for a
considerable share of the overall pollution in Europe. So, the EU set out a set of common rules on
permitting for industrial installations, the so-called Integrated Pollution Prevention and Control
Directive (TPPC 96/6I/EC).
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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In essence, the IPPC Directive is about minimizing pollution from various point sources
throughout the European Union. All installations covered by Annex I of the Directive are required
to obtain an authorization (permit) from the authorities in the EU countries. Unless they have a
permit, they are not allowed to operate. The permits must be based on the concept of Best
Available Techniques (or BAT), which is defined in Article 2 of the Directive. Since the permits
must be based on BAT, the licensing authorities need some assistance to find out which
techniques are BAT. Annex IV of the Directive contains considerations to be taken into account
when determining BAT. Furthermore, the European Commission organizes an Information
Exchange Forum (IEF), which consists of representatives from Member States, industry and
environmental non-governmental organizations. This work is coordinated by the European IPPC
Bureau and it has been divided into some 30 sectors. Each sector of work is addressed by a
specific Technical Working Group (TWG) established for the duration of the work with the
purpose to produce (usually within two years) a so-called BREF (BAT reference document)
which will assist the licensing authorities, in issuing operating permits. All BREFs will be
completed by the end of 2004.
Dr. George P. Gallios, Aristotle University of Thessaloniki
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
PILOT PROJECTS UPDATES
TOOLS FOR POLLUTION PREVENTION
S. K. Sikdar
U.S. Environmental Protection Agency
USA
sikdar.subhas@epamail.epa.gov www.epa.org
The elements of this project, Tools for Pollution Prevention, was provided in earlier reports of
this Pilot Project, specifically in the 1999 Annual Report (NATO CCMS Report Number 238).
Essentially two types of technical tools were recognized to be useful for designing cleaner
products and processes. The first kind, called analytical (or software) tools are used for analyzing,
assessing, predicting, and designing product and process systems. The second kind, called
process (or hardware) tools are derived from science-based knowledge that is mostly derived
from experimental investigation. Green chemistry and syntheses, separation methods are
examples of the second kind of tools. This project is only concerned with the analytical tools.
Here is status of the tools being developed at the National Risk management Research
Laboratory, USEPA, Cincinnati.
Pollution prevention progress (P2P): The Mark in version of P2P, which is Windows-
based, is ready. P2P allows determination of progress made in a change purposely made,
such as using a substitute, or a different process of manufacture.
Waste Reduction (WAR) algorithm: This algorithm, used in conjunction with a
commercial process simulator, allows quantification of pollution emission from a
manufacturing process. The algorithm can then be used to modify the process for
improving its environmental performance. WAR has been commercially available with
the simulator, Chemcad, marketed by Chemstation. It has also been included in several
academic simulators, and has been in use in the Philippines for reducing pollution from
several processes. A commercial collaborator is making a stand-alone version of WAR.
Upgrades for a network of processes are being researched now.
Program for Assisting the Replacement of Industrial Solvents (PARIS II): PARIS II, a
solvent design software, developed by researchers at EPA, was commercialized in 2000,
and is available from TDS, Inc of New York, New York.
Tools for the Reduction and Assessment of Chemical Impacts (TRACI): TRACI is now
ready for testing. TRACI was developed to allow quantification of adverse environmental
impacts of chemicals such as those that are found in products.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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A new tool recently developed correlates chemical toxicity, aquatic and biological,
with structure using the group contribution method. This tool will allow prediction of
toxicity of chemicals for which data do not exist.
LCAccess is an LCA data portal recently launched on the EPA website. This portal
allows access to available LCA data through hyperlinks. It is also a good primer for
LCA.
Various other tools in this analytical tool category are being developed elsewhere. Of
particular mention is the use of the mass exchange network (MEN) analysis, which has been
pioneered by Manousiothakis and El-Halwagy, and has been successfully used in reducing
water use in plants by various workers in the field.
SubhasK. Sikdar, U. S. EPA, Pilot Study Director
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
ENVIRONMENTAL IMPACTS OF HC EMISSIONS IN LIFE CYCLE
ANALYSIS OF GASOLINE BLENDING OPTIONS
T. M. Mata", R. L. Smithb, D. M. Youngb and C. A. V. Costa11
laboratory of Process, Environmental and Energy Engineering. University of Porto,
PORTUGAL
amartins@fe.up.pt
bNational Risk Management Research Laboratory. U.S. Environmental Protection Agency
USA
Changes in gasoline specifications worldwide affect demand for all major gasoline-blending
components. The purpose of this study is to compare different gasoline formulations based on the
accounting of the environmental impacts due to hydrocarbon emissions during the gasoline
production and marketing. Gasoline blending streams used to meet all the specifications are:
reformate, alkylate, cracked gasoline and butane. The two most important variables to consider in
the gasoline blending are the research octane number (RON) and the Reid vapour pressure (RVP)
which are subject to technical and environmental constraints. This study considers two gasoline
octane grades, the 95 and the 98 RON. Among these two gasoline grades several formulations
will be compared, i.e., with a different content of butane, reformate, alkylate and cracked
gasoline. In doing the several gasoline formulations it is important to meet the RVP requirements
defined by the EU Fuels Directive. This study accounts the gasoline losses due to evaporation
and leaks, using existing methods in the literature, and evaluates the potential environmental
impacts, using the Waste Reduction (WAR) algorithm. It includes eight impact categories:
human toxicity by ingestion and by dermal/inhalation routes, terrestrial toxicity, aquatic toxicity,
photochemical oxidation, acidification, global warming and ozone depletion. This analysis
includes the several steps in the gasoline life cycle: the manufacture, storage, loading in tank
trucks, loading in tankers or barges, transit losses during the transportation of gasoline to service
stations, storage at service stations and vehicles refuelling. This study also considers the variation
of the operation conditions of the reforming process, to adjust yield versus octane number, using
process simulation. The calculated values are good estimates of the real process allowing
different aspects to be easily analyzed. Several conclusions came from this study, concerning an
environmental evaluation of the different gasoline options and formulations and about the
operation conditions that should be used in the reforming process in order to met the gasoline
specifications.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
PILOT STUDY WEB SITE
D. Murray
U.S. Environmental Protection Agency
USA
murray.dan@epamail.epa.gov http://www.epa.org
Since the third meeting of the NATO CCMS Pilot Study on Clean Products and Processes in
Copenhagen, Denmark, in May 2000, a pilot study web site has been established. As discussed in
Copenhagen, the purpose of the web site is to enhance communication within the pilot study and
to external stakeholders and customers. The purpose of this pilot project update is to propose
specific applications for the web site and to solicit suggestions from the pilot study delegates.
At this point in time, the web page is designed to first describe the pilot study and provide on-line
reports of the activities of the pilot study. In addition, each participating nation is identified with
appropriate information and links to organizational web sites.
Proposals to be discussed will be to provide interim pilot project status reports on the site, to
develop an international clean products and processes portal site, and to request that each nation
become actively involved in keeping the pilot study web site updated by working closely with
U.S. EPA.
DanielJ. Murray, Jr., U. S. EPA, Pilot Study Co-Director
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
POLICY STATEMENT ON DEVELOPING GOODS AND SERVICES
WHICH MEET PEOPLE'S NEEDS BUT INVOLVE THE USE OF FEWER
NATURAL RESOURCES IN MOLDOVA
S. Galitchi
Ministry of Environment and Territorial Development
MOLDOVA
sergiu@mediu.moldova.md
The methods of investment distribution in the centralized planned economy in the past in
Moldova has generally subjective character with rather political motivations than economic ones,
especially in environment protection area. But however, the organization and management of
interactions between modern society and environment has the goal of current consumption needs
satisfaction, not endangering the future generations needs and aspirations satisfaction.
To implement this policy, government needs adequate instruments. One of them have being
meeting consumer needs and aspirations: how well goods and services meet human needs and
raise living standards and their use makes efficient use of resources.
Taking into account the reality, the values involved in the economic process in Moldova at the
moment (specific for all countries in transition) need a specific functional priority, according to
the necessities of natural resources restoration, their use in an adequate regime of permanent
regeneration and ecologic balance conservation. Natural potential lies at the basis of production
and other economic processes. At the moment in my country is widespread disorientation among
companies often leading them to make decisions, which are incorrect from the
technical/economic/environmental viewpoint and investments, which are disproportionate.
NEW PROCESSES AND MATERIALS FOR ENVIRONMENTALLY
BENIGN SEMICONDUCTOR MANUFACTURING
F. Shadman
University of Arizona. Engineering Research Center for Environmentally Benign Semiconductor
Manufacturing
USA
shadman@erc.arizona.edu http://www.erc.arizona.edu
The rapid growth of semiconductor industry presents special environmental obstacles and
technology issues. These challenges are beginning to have significant impact on both the
development of new processes and the application of new materials for modern 1C
manufacturing. In this presentation, some of the technical issues and potential solutions will be
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discussed and the R&D efforts for developing a new generation of environmentally benign
manufacturing will be reviewed. In particular, examples from the on-going research at the
NSF/SRC Engineering Research Center (a consortium of 7 universities) on this topic will be
discussed. The examples will cover research progress and technology needs in selected areas
including: surface preparation/wafer cleaning, new dielectric materials (high-k and low-k),
gaseous emissions particularly of global warming compounds in lithography and plasma etching,
environmental bottlenecks in chemical mechanical planarization (CMP), and finally,
environmental drivers for process integration in patterning and deposition of dielectrics in
copper/low-k dielectric systems.
Professor Farhang Shadman, University of Arizona
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
PILOT PROJECT ON EVALUATION OF CLEAN
PRODUCTS AND PROCESSES IN MEMBER COUNTRIES
M. Overcash
NATO/CCMS Fellow
Department of Chemical Engineering. North Carolina State University
USA
Overcash@eos.ncsu.edu http://www.che.ncsu.edu/faculty_staff/mro3.html
The concept of sustainable development universally accepted as the means of protecting the
environment for all mankind, demands that future manufacturing technologies must be cleaner,
yet economically sound. With continued industrialization and improving standard of living
among nations, and with increasing globalization of markets and means of production, all nations
by and large are facing similar environmental challenges in the manufacturing sectors. We
established this pilot on Clean Products and Processes to create an international forum where
current trends, developments, and know-how in cleaner technologies, and in tools for measuring
cleanness can be discussed, debated, and shared. We hope that this pilot, through its annual
meetings, will help stimulate productive interactions among experts, with the expected benefits of
effective technology transfer.
A specific part of this pilot study was developed to integrate all the pilot project country members
in sharing cleaner production and products information. The members at the annual meetings
have helped direct the information-sharing activities through selection of specific industry
categories for review. In the 1999/2000 time period, the countries developed responses to
information for their specific country on
the history of the overall program for cleaner production
textile industry sector
These results are found in detail as a part of the Proceedings from the Copenhagen NATO/CCMS
meeting.
Current program
The member country representatives selected for the 2000/2001 time period the following:
Metal Plating/Coating Sector
Food and Agriculture
In general there are questions on the historical development. Then there is a characterization of
each sector. Finally, to help augment the network of those working with each sector to foster
pollution prevention, technical experts are identified.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Questionnaires:
METAL PLATING/COATING INDUSTRY SECTORS
NATO CLEAN PRODUCTS AND PROCESSING PROJECT
Country
For this questionnaire, on the Metal Plating/Coating industry, please respond only for the medium size or larger
part of this industry sector.
1. As of January 2001, for how many years has the industry in your country's Metal Plating/ Coating
Sector been considering and implementing cleaner production changes (in other words, about how old
are the cleaner production programs for Metal Plating/Coating sectors in your country)?
2. Is the Metal Plating/Coating sector considered in the top 5 industrial sectors in your country?
3. In the Metal Plating/Coating industry, are there a large % of small facilities (less than 5-10 people)?
4. Please list the 3-4 of the most commercially attractive cleaner production changes used in the Metal
Plating/Coating industry in your country. Include one or two sentences on each of these 3-4 changes,
if such information is available.
5. What two new ideas for Metal Plating/Coating cleaner production seem to be exciting or of significant
value in your country?
6. Please list 2-3 industrial or technical experts in your country who you believe are the most
knowledgeable in the Metal Plating/Coating cleaner production field. List the full mailing address,
telephone, and email.
PPRCNATOMETALPLATING/COATINGQUESTIONAIRE2001
FOOD AND AGRICULTURAL PROCESSING INDUSTRY SECTORS
NATO CLEAN PRODUCTS AND PROCESSING PROJECT
Country
1. As of January 2001, for how many years has the Food and Agricultural Processing industry in your
country been considering and implementing cleaner production changes (in other words, about how
old are the cleaner production programs for food and agricultural processing sectors in your country)?
2. Is the Food and Agricultural Processing sector considered in the top 5 industrial sectors in your
country?
3. Please list the 3-4 of the most commercially attractive cleaner production changes used in the food
and agricultural processing industry in your country. Include one or two sentences on each of these 3-
4 changes, if such information is available.
4. What two new ideas for food and agricultural processing cleaner production seem to be exciting or of
significant value in your country?
5. Please list 2-3 industrial or technical experts in your country who you believe are the most
knowledgeable in the food and agricultural processing cleaner production field. List the full mailing
address, telephone, and email.
PPRCNATOFOODANDAGRICQUESTIONAIRE2001
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
INVITED PRESENTATIONS
HOW GREEN ARE GREEN PLASTICS?
T. Gerngross
Dartmouth College
USA
tillman.gerngross@dartmouth.edu http://thayer.dartmouth.edu/
Much has been made of the environmental shortcomings of conventional fossil oil based
polymers such as Polyethylene, Polypropylene and Polystyrene. In contrast, biodegradable
plastics that are made from renewable resources have been viewed as a sustainable route to
plastic manufacturing and as such have been regarded as an environmentally friendly alternative.
However, very often an environmental burden is caused by the manufacture of a given product
and only to a minor extent by its ultimate use. Hence a "cradle to grave" analysis, which
incorporates manufacturing practices, resource utilization, land use and overall emissions
becomes the benchmark for assessing the environmental impact of a given product.
We have conducted two life cycle analysis on the production of Polyhydroxyalkanoates (PHAs)
from (1) corn by fermentation, and (2) in genetically modified corn. Both studies strongly suggest
that making PHAs from renewable resources, using current energy usage patterns, have an
overall negative environmental impact when compared to conventional polymers such as
polystyrene or polyethylene. We conclude that biodegradability per se also has environmental
tradeoffs and offer a life cycle view of possible alternatives.
PROGRAMS OF THE U.S. NATIONAL SCIENCE FOUNDATION: AN
OVERVIEW
T. W. Chapman
Director, Separation and Purification Processes Program. U.S. NSF
USA
tchapman@nsf.gov http://www.eng.nsf.gov/cts
The National Science Foundation (NSF), which was founded in 1950, is the single national
agency in the United States with the sole mission of supporting basic research and education in
science and engineering. The Foundation is governed by the National Science Board, and its
Director is appointed by the President. NSF does no research in-house; rather it is one of the
primary sources of funding for research in American universities. The total budget for the current
fiscal year is US $ 4.4 billion.
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The activities supported by NSF are organized around three basic themes: people, ideas, and
tools. All proposals for funding are reviewed by the peer community and evaluated in terms of
two general criteria: intellectual merit and potential impact.
In this talk I shall explain briefly the organization and operating procedures of NSF as well as
some of the programs that may be of interest to this audience. In particular, I will describe the
research initiatives that have a bearing on understanding and protecting the environment. One
current initiative of NSF is called "Biocomplexity in the Environment", and there is a major
effort on Environmental Research and Education. An Engineering Directorate program that is run
jointly with the Environmental Protection Agency, "Technology for a Sustainable Environment",
seeks to promote research on pollution prevention, with an emphasis on Green Chemistry and
Engineering.
In addition to supporting domestic academic research projects, NSF also encourages international
collaboration. There is a Division of International Programs that serves as the U.S. point of
contact for bilateral and multinational science agreements. Although NSF does not support
foreign research activities, the International Division and the disciplinary programs do provide
incremental support to facilitate international collaboration by our scientists and engineers. These
activities are aimed not only at enhancing research progress but also at human-resource
development.
In this talk I shall try to identify opportunities through NSF for increased cooperation between
U.S. and European colleagues with common interests, such as the development of clean products
and processes.
Professor Thomas W. Chapman, U. S. National Science Foundation, explaining NSF activities
42
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
COMPUTER DEMONSTRATIONS
NATO/CCMS CLEAN PRODUCTS AND PROCESSES WEB SITE. U.S.
EPA - LCACCESS
D. Murray
U.S. Environmental Protection agency
UNITED STATES OF AMERICA
murray.dan@epamail.epa.gov http://www.epa.org
The NATO CCMS Pilot Study on Clean Products and Processes web site and U.S. EPA's
LCAccess web site will be demonstrated.
The Pilot Study web site (http://www.epa.gov/ord/NRMRL/nato) contains background
information on the pilot study, electronic copies of the annual reports, and information on each
nation actively involved in the study.
The U.S. EPA's LCAccess web site (http://www.epa.gov/ord/NRMRL/LCAccess) was recently
established by the National Risk Management Research Laboratory and is a portal to on-line life
cycle assessment (LCA) data. The purpose of the site is to promote LCA and to provide a single
point of departure for accessing the wide range of data available from sources all over the globe.
By demonstrating the site, U.S. EPA hopes to encourage use and participation by the national
delegates.
Computer demonstration
43
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
ENVIRONMENTALLY FRIENDLY TECHNOLOGIES DATABASE
W. Zadorsky
Ukrainian Ecological Academy. Ukrainian State University of Chemical Engineering
UKRAINE
ecofond@ecofond.dp.ua http://www.zadorsky.8m.com
The presentation is devoted to some of offered by the author more than 300 inventions at
ecologically friendly technological processes, among which many are developed within the
framework of CP program for working manufactures, are submitted in database "Commercialised
CP Technologies Virtual Market" (http://www.zadorsky.8m.com). There are the next groups of
the processes:
Commercialized environmentally friendly technologies
Extension of Ecologization Concept to Cleaner Production
Catalyst impregnation
Impregnation of electrodes and other carbon/graphite articles
Impregnation of textile fibers, and fiber reinforcements of resin-matrix composites
Solid-liquid extraction for pharmaceutics, food processing and pulp industry
Adaptation and rehabilitation program of ecologically intense zones inhabitants
Ecological Equipment and Environmental Protection
Elaboration of the ecologization conception of cleaner production
Electroaerosole Equipment and Methods
Flexible Manufacturing for Chemical Processing
Natural and Wastewater Treatment Technology and Instrumentation
Pollution Control Equipment and Environmental Protection
Pulsed Voltage Converter for Electric Filter Power Supply
State-of-the-Art Approaches to Aerobic Fermentation Engineering
The program and experience of education retraining at theory and practice on cleaner
production
Treatment of Natural and Waste Water
Manufacturing
Converter of a Voltage's Pulsing to Power Supplies of Electric Filter
Flexible Production Systems
Electrosol painting
44
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Equipment and Materials
Acoustic Equipment for Intensification of the Mass-Transfer Processes
New Impregnation Thermotechnology of Production
Technology for deep purification of liquids
Electrosol Apparatuses and Methods
Flexible Manufacturing Systems for Chemical Processing
Utilities
Improving water quality through low-cost upgrading of a water treatment facility
accompanied by abandonment of chlorination
ON-LINE VIRTUAL CLEANER TECHNOLOGY INCUBATOR
W. Zadorsky
Ukrainian Ecological Academy. Ukrainian State University of Chemical Engineering
UKRAINE
ecofond@ecofond.dp.ua http://www.zadorsky.8m.com
One of the most perspective directions of mutually beneficial collaboration is a creation of the
Virtual on-line TECHNOLOGICAL CP BUSINESS-INCUBATOR (VTBI-CP) "INTELLECTUAL
SERVICE". VTBI-CP will be a commercial NET with the next basic blocks:
Virtual Investment Market of enterprises and organizations (which want to invest) web-
sites/pages, Internet Data Base of professionals and organizations in the field of investment
expertise, search engines on and links to investment legislation in different countries, Web
pages on and links to investing institutions and individuals (i.e. funds, banks, state
organizations, investment companies and corporations, etc.), information in Internet on
grants, subsidies, sponsor help, Web-page/sites, business proposals and projects' plans pulled
out for investing).
Technologies Transfer Market (search engine systems on patented information in different
countries, Web - Page/sites, presentations on technologies transfer in the different fields).
Services (scientific and technical consulting, audits, examination, project management, search
for partners, search for investors, grant programs, tenders, advantageous credits, etc., support
in fundraising, legal service, patenting, examination and consulting on scientific and technical
solutions to improve industrial technologies and equipment, to solve ecological problems as
well energy-saving ones, etc., business-planning, Web site design on international standards,
preparation of projects, international conferences, exhibitions and fairs' presentations in
INTERNET and mass media).
45
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Training and consulting (on-line training programs on business, foreign languages,
management, marketing, decision making theories, system analysis, theories of system
sustainable development, work in Internet, consulting services, links to universities involved
in activity similar to VTBI subjects).
Besides wide program of mutually beneficial collaboration will be offered: joint scientific
research, including participation in international scientific programs and joint developments for
industrial enterprises and other organizations, transfer of new high technologies, joint analysis of
developments in science, industry, education and social policies in the NTS countries, joint
research in permanent areas of applied chemistry, chemical processing and chemical engineering,
chemical industry, metallurgy, engineering, food-processing and pharmaceutical industries,
exchange of leading scientists and specialists, exchange of visiting professors that deliver lectures
on the chosen themes.
FOSTERING RESOURCE EFFICIENCY THROUGH NETWORKING AND
CONVENIENT INFORMATION ACCESS - GERMANY'S
CLEARINGHOUSE COOPERATIVES ON CLEANER PRODUCTION IN
THE WORLD WIDE WEB
H. PohleaandK. Wessef
aFederal Environmental Agency (UBA)
GERMANY
horst.pohle@uba.de
Sonderabfall-Management-Gesellschaft Rheinland-Pfalz mbH (SAM)
GERMANY
pius@sam-rlp.de
The access to technology and management information is crucial for further implementation of
cleaner production processes in companies. With two new Internet gateways, Germany supports
this demand to foster sustainable development in industry. The German Federal Environmental
Agency (UBA) has established the first version of the website "www.cleaner-production.de".
Cleaner Production Germany (CPG) is a federal Internet information system for innovative
environmental technology and federal projects in Germany and a gateway to technology transfer
and contacts. The PIUS Internet Forum under www.pius-info.de is closely linked with CPG. It is
a cooperative web project of currently five German states with new partners to be acquired. The
large database of pollution prevention projects conducted in companies offers detailed
information about technology, experiences, costs and management. By extending the two
cooperating Internet platforms Germany wants to boost international environmental and
development cooperation and promote the transfer of environmental technologies.
46
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
POSTER PRESENTATIONS
CLEANER PRODUCTION OF FARMERS AND FOOD PRODUCERS IN
THE CZECH REPUBLIC
A. Christianovd11, F. Bozekb, J. Dvozdkb and A. Komdrb
aCleaner Production Centre
CZECH REPUBLIC
bMilitary University Vyskov
CZECH REPUBLIC
bozek@feos.vvs-pv.cz Komar@vvs-pv.cz
Principles of cleaner production in agricultural and food industries are introduced in the Czech
Republic through the projects of cleaner production. The projects are aimed at family farms, co-
operative farms and food-processing companies of different sizes. Projects of the Czech Cleaner
Production Center are implemented not only in individual companies, but also within the
framework of regional programs. Regional program is the instrument of municipal environmental
policy that helps to support sustainable development.
Five papers present the following topics: regional program of cleaner production and the scheme
of its implementation procedure, examples of project implementation on a farm, in a co-operative
farm and a food delivering company, and the activities of the Czech Cleaner Production Center.
ENVIRONMENTAL IMPACTS OF HC EMISSIONS IN LIFE CYCLE
ANALYSIS OF GASOLINE BLENDING OPTIONS
T. M. Mata", R. L. Smithb, D. M. Youngb, and C. A. V. Costa11
laboratory of Processes, Environmental and Energy Engineering. University of Porto
PORTUGAL
amartins@fe.up.pt
bNational Risk Management Research Laboratory. U.S. Environmental Protection Agency
USA
Changes in gasoline specifications worldwide affect demand for all major gasoline-blending
components. The purpose of this study is to compare different gasoline formulations based on the
accounting of the environmental impacts due to hydrocarbon emissions during the gasoline
production and marketing. Gasoline blending streams used to meet all the specifications are:
47
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
reformate, alkylate, cracked gasoline and butane. The two most important variables to consider in
the gasoline blending are the research octane number (RON) and the Reid vapor pressure (RVP)
which are subject to technical and environmental constraints. This study considers two gasoline
octane grades, the 95 and the 98 RON. Among these two gasoline grades several formulations
will be compared, i.e., with a different content of butane, reformate, alkylate and cracked
gasoline. In doing the several gasoline formulations it is important to meet the RVP requirements
defined by the EU Fuels Directive. This study accounts the gasoline losses due to evaporation
and leaks, using existing methods in the literature, and evaluates the potential environmental
impacts, using the Waste Reduction (WAR) algorithm. It includes eight impact categories:
human toxicity by ingestion and by dermal/inhalation routes, terrestrial toxicity, aquatic toxicity,
photochemical oxidation, acidification, global warming and ozone depletion. This analysis
includes the several steps in the gasoline life cycle: the manufacture, storage, loading in tank
trucks, loading in tankers or barges, transit losses during the transportation of gasoline to service
stations, storage at service stations and vehicles refuelling. This study also considers the variation
of the operation conditions of the reforming process, to adjust yield versus octane number, using
process simulation. The calculated values are good estimates of the real process allowing
different aspects to be easily analyzed. Several conclusions came from this study, concerning an
environmental evaluation of the different gasoline options and formulations and about the
operation conditions that should be used in the reforming process in order to met the gasoline
specifications.
CERAMIC MEMBRANES IN CLEAN PROCESSES IN RUSSIA
G. G. Kagramanov
Moscow Mendeleyev University of Chemical Technology of Russia
RUSSIA
kadri@muctr. edu.ru http ://www.muctr. edu.ru
The development of inorganic membranes in Russia began in early 40-s of XX-th century and the
main industrial application was the separation of gases. In the 80-s of the last century various
research groups and industrial enterprises were concentrated due to special program, financed by
government, for the development of ceramic membranes technology, production and realization
of membranes and units. Due to this program the technologies of micro-, ultra- and nanofiltration
ceramic membranes based on A^Os, ZrO2, TiO2, SiO2, CeO2, SiC were developed and various
processes and applications were studied. The first industrial output of ceramic microfiltration
membranes started in 1989 in Moscow region. The rate of ceramic membranes production in
Russia (100 m2 in 1989) reached 950 m in 1993 and 2 100 m2 in 2000. Basic industrial
applications, designs and technological data of ceramic membrane units for clean products and
processes in food industry (purification of wines, juices, vodka etc.), pure and waste waters
treatment, microbiological and pharmaceutical branches of industry (filtration of biomass, culture
broths etc.) are discussed.
48
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
TOOLS AND METHODS FOR CLEAN TECHNOLOGIES
W. Zadorsky
Ukrainian Ecological Academy. Ukrainian State University of Chemical Engineering
UKRAINE
ecofond@ecofond.dp.ua http://www.zadorsky.8m.com
The scientific analysis of the production interaction with the environment allows to estimate the
direction toward improving the technological processes, which would reduce their negative
influence on the environment, it is possible only based on system-structural analysis of the
ecologization of production. Then it would be possible to consider the interaction between nature
and man based on a complex systematic approach founded on the apprehension of the fact, that
the technical equipment is only a part of the all system. Therefore the tendency to harmonize the
relationship of nature with technical equipment, where the operation of industrial complexes is
tied not only to the technogenic activity of man and the use of technological objects, but also to
the state of natural environment becomes evident. The ideal solution of the problem would be the
creation of nature-technical system allowing to achieve high technical indices at favorable
ecological condition.
As it is often impossible to reduce the level of negative influence of the production on the
environment without modifying of the technological processes, the activity to improve the current
ones or creating principle new technological processes directed not only to solve the utilitarian
problems, but also to protect the environment.
Approach to global ecological crisis compels to take into consideration the influence of industry
on environment. It's need a quantitative indexes characterizing the influence not only for
estimation measure of influence of the production but for prognosis of technogenic influence of
the enterprises being projected or for securing given level of technogenic influence.
A classification scheme is developed, showing the interrelation of the main conceptions of
ecologization of the production with the methods of their realization.
ENVIRONMENTAL BIOTECHNOLOGY IN THE QUESTOR CENTRE
/. Swindatt QBE
QUESTOR Center. Queen's University
UNITED KINGDOM
j .swindall@qub.ac.uk http://questor.qub.ac.uk
This poster outlines the various strands of environmental research in the QUESTOR Centre
(Queen's University Environmental Science and Technology Research) that have a
biotechnology aspect.
49
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
THE QUEEN'S UNIVERSITY IONIC LIQUID (QUILL) RESEARCH
CENTRE
/. Swindatt QBE
QUESTOR Center. Queen's University
UNITED KINGDOM
j .swindall@qub.ac.uk http://questor.qub.ac.uk
This poster describes the features of the QUILL Research Centre. It includes a brief description
of ionic liquids, the areas of IL research in QUILL and also charts showing, respectively, the
growth of papers on ILs over the past 20 years and the IL publications by author to date.
CATALYTIC TREATMENT OF GASEOUS EMISSIONS FROM COKE
OVENS
L. S. Escandon, M. A. G. Hevia, J. R. Paredes, P. Hurtado, S. Ordonez and F. V. Diez
Department of Chemical & Environmental Engineering. University of Oviedo.
SPAIN
http://www.uniovi.es/~ingenieria.quimica
Introduction
Many of the gaseous emission problems in the iron and steel-making industry have been solved
by improving the existing production technology or by adopting suitable treatment technologies.
In the last years great progress has been made in controlling dust emissions. Dust is controlled by
protecting open piles, watering roadways, covering conveyor belts and transfer points, controlling
fumes through improved casthouse practices and air cleaning systems ducted to bathhouse or
other filtration systems. Sulfur dioxide emissions are controlled using off-gas and stack cleaning
systems. Great progress has also been made in controlling fugitive emissions (emissions that
enter the atmosphere from other places than a stack, chimney or similar device) such emissions
occur when pollutants are not captured by a control device or are generated without employing
control measures. Significant sources of fugitive emissions in the iron and steel industry include
coke ovens, sinter plants, blast furnaces, steel converters, teeming, casting and rolling plants. For
instance, recent technological developments for reducing coke oven fugitive emissions include
leak-free oven doors and hoods for collecting emissions during coke oven charging and pushing.
There still exist, however, several emission sources of gaseous pollutants for which treatment is
lacking or not satisfactory. As a matter of fact, while sulfur dioxide and particulates are usually
eliminated from controlled emissions, treatments for eliminating other chemicals are often
incomplete, specially for volatile organic compounds (VOC). In the other hand, there are still
numerous sources of uncontrolled fugitive emissions in the iron and steel plants.
50
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
One example of this type of emissions is given by the coke production process. Most of the gas
generated during the coking process is suitably collected and treated, but other emissions are
produced by leakage from coke oven doors and during the charging and discharging processes.
These emissions contain dust, inorganic gases, such as H2S and NH3, CH4 and VOCs including
toxic ones: ethylene, propylene, toluene, xylene and benzene. In the last years, the concerning
about the methane emissions increases a lot, because of the important role of this compound in
the global warming.
Other significant sources of fugitive emissions (in the iron and steel industry) include sinter
plants, blast furnaces, steel converters, teeming, casting and rolling. Besides, the composition of
these gaseous emissions varies according to the location of the leak and varies also with time, as
they are related to non-steady state processes or to accidental emissions.
All these emissions, although being considered small in comparison with the total volume of
emissions in this type of industry, represent a considerable impact on the environment, taking
into account the size of the European iron and steel industry and the hazardous character of the
compounds released. In view of an increasingly deeper control of the atmospheric pollution,
required both socially and by the ever more restrictive environmental regulations, it is necessary
to treat them using adequate "end-of-pipe" processes.
The USA classified these emissions as hazardous air pollutants under the Clean Air Act.
According to the EEC Protocol on VOC Emissions, signed in November 1991 by 23 European
countries, VOC emissions should be reduced by 30% by the year 2000 (with regard to the base
year 1988). The committed countries also agreed on imposing maximum emission standards on
their industries by 1994. Furthermore the best available technologies for an economical VOC
removal must be installed by 1997 in all existing companies. These new targets on VOC
emissions can no longer be achieved in an economical and cost efficient way with the current
technologies of active carbon adsorption and thermal incineration, and existing catalysts for
catalytic incineration must be adapted to the specificities of the gaseous emissions generated by
the iron and steel industry.
Although the production of coke in the iron and steel industry might become superfluous in the
future due to the development of the so-called "direct reduction" technology, it is widely accepted
that the blast furnace process will remain dominant during at least the next 30 years.
Coke oven emissions
The results here presented correspond to a Research Project, financed by the European Union
with the participation of Aceralia Corporation Sidenirgica, the main iron-making company of
Spain, the Catholic University of Lovaine (Belgium) and Technical University of Turin (Italy).
The scope of this project was the study of the coke oven emissions. Three important fugitive
emissions are produced in the operation of a coke oven (Fig. 1):
51
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
Doors leaks-
Charging emissions j*
Caps leaks
Pushing emissions
Pushing emissions
i.
Figure 1. Main coke oven emissions
Emissions produced in the pushing of the coke^ These emissions are the less important from
an environmental point of view, the main pollutant detected were CO and specially CC>2,
produced by coke combustion in presence of air.
2. Emissions from leaks of oven caps and doors. These emissions are the most pollutants, they
content high amounts of VOCs, PAHs, and sulfur and nitrogen compounds. The caption and
treatment of these emissions is very difficult, but these emissions are avoidable with a good
maintenance of the ovens.
3. Charging emissions. These emissions are the gases contained in the empty oven, which are
displaced when the oven is charged with coal. The device utilised to coal charging has a
blower to extract these gases. The pollutants found in these streams are the same than in the
case of leaks, the concentration depending strongly on the blower performance.
Typical compositions of the three emissions are shown in Table 1. The most important emissions
are the charging emissions since they are unavoidable and they present important concentration
of pollutants. Furthermore, charging emissions are water saturated because of the use of a water
shower to remove particulates from the emissions.
52
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Table 1. Typical composition of coke oven emissions (ppmV). Details about analytical methods
are given in references [2,3]
Compound Charging emissions Pushing emissions
emissions
CO
CO2
CH4
H2S
S02
NH3
NO2
C2H4
C2H2
H2
1500
1450
2710
15
23
176
29
(.<.
cc
cc
210 3120
57800 2890
18800
55
40
545
23
1950
1570
33000
However the treatment of these emissions must afford another problem which is not present in
the treatment of other polluted gaseous streams: their unsteady character. These emissions are
produced during 3 minutes (with no constant flow and concentration), with a variable time
interval, which depends on dimensions of coke oven, coal residence time and other operational
factors.
Treatment technologies: catalytic incineration
Although many technologies are described in the literature for the abatement of organic
compounds in gaseous emissions [1], the flow and composition of the studied emissions make
difficult the technology selection. Gas adsorption is not efficient for light hydrocarbons (such as
methane), the operation of biofilters is hindered by the presence of sulfur and nitrogen inorganic
compounds, whereas thermal incineration is not appropriate because of the needing of big
amounts of additional fuel (which could be very dangerous in the environment of a coke oven
battery).
Catalytic incineration seems to be the most interesting alternative, in spite of the pernicious effect
of the sulfur compounds on the performance of the most of the catalyst [4]. It is important to
remark that methane is considered as the organic compound most refractory to catalytic
oxidation. Due to this reason, subsequent studies are centred in the catalytic oxidation of
methane, all the other VOCs being removed at conditions need to methane oxidation.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Although catalytic oxidation is a very studied and utilised technique, there are not studies about
the behaviour of the catalysts at these aggressive conditions. So the first part of our work was
devoted to test the available oxidation catalysts in lab reactors.
Three aspects have been considered: the activity for methane oxidation, the catalyst resistance to
deactivation in this environment and the effect of the cyclic working in the catalyst performance
and deactivation. The selected catalyst has been tested in situ in a bench scale reactor.
Experiments in a lab-scale reactor
The lab-scale reactor used in this work is a stainless cylinder of 400 mm length and 9 mm
internal diameter. Catalyst (typically 0.3-1 g) is diluted with inner glass is placed in the middle
section of the reactor, the upper and lower parts of the reactor being partially filled with
additional packing material. The reactor is placed inside an electric furnace. Reaction temperature
is monitored by a thermocouple placed inside the rector and controlled by a PID controller, acting
on the electric furnace. The reactor feeds are produced by mixing gas streams coming from gas
cylinders, when liquid reactants are used (i.e. water), they are fed using a precision syringe pump.
Reaction products are analysed by gas chromatography.
1. Catalyst screening
The following catalysts have been chosen to be studied for the destruction of methane and other
pollutants:
Precious metals catalysts:
RO-25/50 BASF, 0.50 wt.% Pd/Al2O3
Escat 26 ENGELHARD, 0.50 wt.% Pt/ A12O3
Escat 36 ENGELHARD, 0.50 wt % Rh/ A12O3
211 H/99 SUD-CHEMIE, 0.1 wt % Pd, 0.1 wt % Pt/ A12O3
Metal oxides catalysts:
R3-20 BASF, CuO 7 wt.%, Cr2O3 14 wt.%, TiO2 71 wt.%
In order to select the best commercial catalyst, light-off curves and ageing experiments in
presence of a hydrocarbon, a sulphur compound (hydrogen sulfide) or a nitrogen compound
(ammonia) were carried out in a fixed bed reactor. Details of the experimental set-up and
analytical procedures were given in reference [5]. The reactor was fed with 2000 ppmV methane
in air. In the light-off curves the space time in all experiments was 2.3 min g/mmol methane,
except for the BASF mixed oxides catalyst, for which space time was increased to 15.2 min
g/mmol methane. In the case of ageing studies the selected temperature was 450ฐC for all
catalysts (except for the mixed oxides one, for which temperature was fixed at 600ฐC). Space
times used in the ageing experiments for the different catalysts were varied between 2.3 and 15.2
min-g/mmol, depending on the catalyst activity. Some results are presented in Figs. 2 and 3.
54
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
100
C^ 80 -
I 60 "
ฃ 40 -
=
U 20 H
A A C
B ซD
A-
A
A
A
200 400 600
Temperature (ฐC)
800
Figure 2. Light-off curves for the selected catalysts: A: RO-25/50 BASF, B: Escat 36
ENGELHARD, C: 211 H/99 SUD-CHEMIE, D: R3-20 BASF
Conversion (%)
80 '
60
40
20 -
n
*
it
VS&SSKte-^
7^s^ " ~ "/J" fc
A RO-25/50 BASF
. Escat 36 ENGELHARD
Escat 26 ENGELHARD
.211 H/99 SilD-CHEMIE
R3-20BASF
0 5 10 15 20
Time (h)
Figure 3. Ageing experiments with the selected catalysts
The following conclusions can be obtained from these experiments:
The most active catalysts for the deep catalytic oxidation of methane are the catalysts
containing palladium and rhodium.
Palladium and rhodium catalysts suffer a sharp deactivation during the first hours of
experiment, conversion decreasing then slowly. On the other hand, although the decrease in
conversion for the platinum and mixed oxides catalysts is less pronounced, the conversion is
very poor at the same experimental conditions
According to these results, the palladium catalyst was selected to be studied more in depth. In
other hand, the two inorganic compounds that affect the catalyst performance in higher extension
are shown to be water and sulphur compounds.
55
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
2. Cyclic studies
These experiments were carried out using the selected palladium catalyst. The experimental
conditions were the following: space time: 11 g.min/mol; temperature: 450ฐC; concentration of
pollutants: 5000 ppm methane, 65 ppm SO2, 27000 ppm H2O, 180 ppm NH3. Results for the
methane-water mixture show that the catalyst recovers its initial activity when steam is removed
from feed. On the other hand, results in the presence of SO2 indicate that the recovery in the
catalytic activity is only partial when 862 is not fed to the reactor (Figure 4).
^
ฃ
s
2
i.
>
a
o
U
80
60
40
20-
0
r ^umaetMtMitettetti
aP/"^^""B ซ CH4
A CH4+H2O
A iCH4+SO2
i CH4+SO2+H2O
* CH4+SO2+NH3+H2O
i
X
X "A ^..^XXXXXX*****************
A .X*"?*
v A * '
\ *'<
**X*LXX
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
Gas inlet
Metallic net
Glass spheres (3 mm)
Catalyst
Glass spheres (4 mm)
Gas outlet
Figure 5. Scheme of the reactor and of the experimental set-up used in the plant experiments:
1. Exhaust gas, 2. Particle removers, 3. Filter, 4. Rotameter, 5. Inlet gas sampling, 6.
Reactor, 7. Outlet gas sampling, 8. Pump
Two sets of experiments were carried out, both with the selected commercial catalyst (BASF
0.5% Pd/Al2O3). The first set of experiments was carried out at high space time (0.029
s-m3cat/Nm3) and two different temperatures (450 and 550ฐC), for up to 15 successive cycles of
operation. Each cycle lasted aprox. 4 min and they were spaced aprox. 10 min. The aim was to
confirm the ability of the reaction system to get high conversions in the catalytic combustion of
methane for the real effluent. In these experiments a good performance of the system was
observed, as can be seen in Fig. 6, the methane concentration at the reactor outlet being always
lower than 18 ppm, for inlet concentrations ranging between 100 and 6000 ppm. In spite of the
presence of sulfur compounds in the reactor feed, no important catalyst deactivation was
observed during these experiments. This is confirmed in Fig. 7, in which it is observed that
methane conversion does not depend on the number of cycles of operation. This figure shows as
well that the lower the inlet methane concentration, the lower the conversion obtained (result
expected, from the point of view of the lower heat of reaction generated at low concentrations).
The second set of experiments was devoted to study the deactivation for the catalyst at lower
space time in real industrial conditions. For this purpose, a low space time (0.0089 s-m3cat/Nm3)
was selected, in order to observe the deactivation of the catalyst. The results are shown in Fig. 8,
where the catalyst deactivation with the increase of operation cycles can be observed, if data
obtained for very low methane inlet concentration (an hence low conversions) are discarded.
Conclusions obtained in the real plant agree with those obtained in the lab experiments,
indicating that the strategy of studying the behaviour of the catalyst at lab scale with synthetic
gaseous mixtures of different complexity was adequate.
57
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
20
S 10
o
D T 550ฐC
D T 450ฐC
1 3 5 7 9 11 13 15
Charging cycles
Figure 6. Methane concentration in the outlet
of the reactor
1UU'
90
80-
70
60
50-
40-
30
20-
10-
n
9 ซ?o *
.15 9
ป
7 13
,11
ซ3
1 =* 11 3
T = 450ฐC
ซ T = 550ฐC
*<
0 0.1 0.2 0.3 0.4 1 2 3 4 5 6
CCH4/1000 (ppm)
Figure 7. Conversion vs. outlet methane
concentration (small digits indicate the number
of cycles)
100
80-
a 60-
e
U
40-
20-
ป 550 ฐC
o 450 ฐC
0 2 4 6 8 10 12 14 16 18 20
Charging cycles
Figure 8. Methane conversion vs. number of charging cycles. Experiments at low space time
References
1. Mukhopadhyay, N; Moretti; E. C. "Reducing and controlling volatile organic compounds".
American Institute of chemical Engineers, Center for Waste Reduction Technologies. New
York, 1993
2. APHA; AWWA; WPCF; "Standard Methods for the examination of water and wastewater",
American Public Health Association, Washington, 1980
3. Sloss L. L.; Gardner C. A.; "Sampling and analysis of trace emissions from coal-fired power
station", IEA Coal Research, Londres, 1995
4. Lee, J. H.; Trimm, D. L. "Catalytic combustion of methane". Fuel Proces. Tech., 42 (339-
359), 1995
5. Hurtado, P. "Catalytic abatement of gaseous pollutants emitted from siderurgical coke
production", Ph D. Thesis, University of Oviedo, 2001.
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April 2002
UNIVERSITY-INDUSTRY CO-OPERATION PRESENTATIONS
QUESTOR/QUILL UPDATE
/. Swindatt QBE
QUESTOR Center. Queen's University
UNITED KINGDOM
j .swindall@qub.ac.uk http://questor.qub.ac.uk
This presentation will outline the current status of both the QUESTOR and QUILL
Industry/University Co-operative Research Centers (IUCRC). In addition the development and
operation of the new Applied Technology Unit (ATU) of QUESTOR will be described and in
addition the progress made founding QUESTOR Technologies Ltd, the spin out company with
three environmental products arising from research within QUESTOR.
Progress with the establishment of QUMED, the new IUCRC for medical devices combining
medicine, engineering and science in Queen's University will also be described.
Professor Jim Swindall, Queen's University
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
UNIVERSITY/INDUSTRY RELATIONS IN SPAIN
J. Coca
Department of Chemical & Environmental Engineering. University of Oviedo.
SPAIN
jcp@sauron.quimica.uniovi.es http://www.uniovi.es/~ingenieria.quimica
The university in Spain is one of the oldest institutions in the country and in Europe. As an
example, the University of Salamanca, founded in 1254, boasted above ten thousand students in
the fourteenth century, and played an important role in many historical events, like the discovery
of America by Columbus. The role of the old universities for many centuries was to give advice
to the kings and queens, to work on new laws and to educate the future priests for the church.
For many centuries, and perhaps till the second half of the XX century, the main issue of the
Spanish universities was to provide society with professionals that could find jobs in the
administration, industry, educational institutions, services and some private initiatives. In the
period 1950-1975 some research efforts were made in the university sponsored by very modest
state programs, always carried out with a lack of infrastructure and equipment, and with no
communication channels with industry.
In that period of time the Spanish industry supplied the goods to the national market and the
protectionist barriers towards imports, made out of most companies "production tools", in an
environment with no competition from other nations. As a result, there was no incentive for
scientific and technological innovation and also no basic need for a partnership of universities
and industry. The research carried out in the university was mainly basic research, of limited
scope, and in areas based on the interests or skills of the professor.
Roughly, in the last quarter of the XX century, an increasing funding of research activities was
established and working relationships between companies and universities increased and were
enhanced by European, national and regional research programs.
The aim of this article is to describe the major changes undergone by the Spanish universities in
the last 25 years, the main sources of research funding and their implications in promoting
university-industry cooperation.
The evolution of Spanish universities
The last quarter of the XX century has been a period of time of big changes in the Spanish
universities. Until the late 60's there were in Spain 12 public universities and 2 private ones. The
student population in each university was well below 10 000 students, with the exceptions of
Madrid and Barcelona that had a larger number. The university consisted of Faculties of
Humanities, Sciences, Medicine and Law and Schools of Engineering and Architecture. There
was a departmental structure, and very often the department had only one full professor, 2-10
assistant professors and several teaching assistants. Tuition in those days was of the order of 3000
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
pesetas (18e, of year 2000) per academic year. The departmental budget was very low and it
was spent in buying a few books and journals and to support laboratory courses.
Along those years and till the present days the number of Spanish universities has increased to 58
in the public sector and 8 in the private sector. The constant pressures for demand of university
studies has increased the number of students in the small universities quite often up to 40.000.
The expanding number of students and knowledge, the urgent need of more professors and the
more research-oriented university has brought radical changes in the university structure in the
last 25 years. The departments have now several full professors, a larger number of assistant
professors, but fewer teaching assistants, because of their fast promotion. Tuition has also
increased and on the average is now 100 000 pesetas (590 e) per academic year, still low if
compared with American public universities and some European. The departmental budget has
also increased and new chapters are available such as: infrastructure, equipment and library.
In the year 1983 a new University Law was approved by the Spanish parliament (Ley de Reforma
Universitaria, LRU). The law was intended to accommodate the university structure and
organization to the changes and demands of the society and had a substantial impact on how the
rector was elected and how professors were appointed. It also created new decision bodies and,
last but not least, established the framework for the university-industry relations, that did not
have a legal support till the new law LRU was passed.
Another keystone for promoting research in the university and other research institutions was the
Science Law which was proclamed in 1986. A science and technology committee called CICYT
(Comision Interministerial de Ciencia y Tecnologia) was established as a result of the new law,
with representation of the different ministries involved in science and technology activities. In
1998 a science and technology agency, OCYT (Oficina de Ciencia y Tecnologia), was
established which works closely with CICYT in the planning, coordination and evaluation of
science and technology activities.
Research schemes for collaborative research with industry
In Spain R&D activities are carried out at the University, National Research Council (CSIC),
Industry and Research institutes. The number of researchers is roughly 100.000 of which 30.000
are at the university, 20.000 at the CSIC, 35.000 in industry and 15.000 at research institutes. The
number of researchers is of the order of 6% of the active population, lower than in other
European countries with similar economic standards.
The research budget of all the Spanish universities is 190.000 Mpts (1.188 Me) and 110.000
Mpts (0.688 Me) for CSIC and research institutes. The total research expenses account for 0.9%
of the IRP, well below the United States and Japan (3%) or Germany and France (2.5%). More
than 60% of the published research is carried out at the university.
Every three years a national research plan is established and usually coordinated with the
research priorities of the research programs of the EU. The present one corresponds to the period
2000-2003 and is coordinated with the Fifth Framework Program of the European Commission.
There are three basic sources for research grants:
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
National programs: CICYT, Ministry of Environment, etc.
Center for Industrial and Technology Development (CDTI)
Regional programs: Science and Technology Foundations (FICYT, etc)
European Union programs: FEDER, BRITE, etc.
Industry
Project proposals applying for funding in the national and regional programs are sent to the
national evaluation agency (ANEP) and granting for those approved is decided by specific
committees. The CDTI is basically an industrial source for financing through low interest loans
development projects carried out by industry, eventually with some cooperation from research
institutions.
The regional programs try to promote collaborative research and development projects with
industry, and usually 60% of the budget goes for that purpose. The industry is required to
participate with at least 10% of the total funding of the project. The regional programs have been
very useful to promote regional development and regarding cooperation with the local
companies, that sometimes do not have the critical size to do their own research. Through the
regional programs researchers doing basic research have found incentives towards working with
industry.
The European Union research programs have also been very useful for the cooperation with some
Spanish companies. Working with other European partners is always very stimulating and gives a
major incentive for universities and industry to work together.
Research projects supported by industry and to be carried out in the university are still very
scarce in Spain. Most of them are of applied research, and have to be carried out at the most in
one year period, which is too short taking into account the university structure, based mainly on
students as research personnel. The overhead costs hold by the university are 12% of the total
project amount.
There are still some problems to reach an optimum collaboration between industry and
universities, such as: university pressures for publication of results, low funding for applied
research, no secure sustainability of an applied research project once the program comes to an
end, lack of efficient interface structures for technology transfer and scarce research support by
multinational companies operating in Spain.
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SPECIAL TOPIC PRESENTATIONS ON ENVIRONMENTAL CHALLENGES
IN PROCESS INDUSTRIES
PRINCIPALITY OF ASTURIAS: ENVIRONMENTAL POLICY
T. Coca andH. Sastre
Government of the Principality of Asturias
SPAIN
http://www.princast.es
In the last century, the world has suffered an extraordinary development, reaching high levels of
social welfare. The increase on production and consumption implies the possibility of depletion
of the natural and energetic resources and the impossibility of the natural regeneration
mechanisms to accept the environmental impact.
The situation on the region of Asturias is no different to other parts of the country. The
circumstances that we live show the conflicts that the human being has created in our
environment.
The establishment of the Environmental Council by the Government of the Principality of
Asturias reflects the importance that the environment has taken in the last years. It is established
as a unique management body, dealing with all the environmental issues of the regional
administration.
The objectives of this administration are to find, study and give solution to the environmental
problems relevant to Asturias. To approach such problems the structure of the Environment
Council is divided in three main areas: water, environmental quality, and natural resources.
The general lines of action consist of:
Integration of the environment on the rest of the politics
Inter-administrative co-ordination
Improving the enforcement of the environmental regulations
Raise public awareness and support public collaboration
International collaboration
Re-orientation of the market mechanisms
Environment as a development element
Environment, research and development.
Some of the work carried out so far by the Environmental Council is as follows:
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Implantation of a wastewater tax to be able to cope with the expenses of investment
and maintenance of the plants
Creation of a wastewater treatment committee
Project and construction of a composting plant for organic waste
Investment to improve waste treatment facilities
Regeneration of contaminated soils
Collaboration between administration and the main industries for improving the air
quality
Clean up of rivers from any possible obstacles for the fish
Construction of salmon scales on main reservoirs to promote the growth of the
salmon
Awarded two Biosphere Reserves by the UNESCO
Design of a web page for public information
Establish a new natural park
Plans for the recovery of the bear, etc
ADVANCES IN ENVIRONMENTAL ASPECTS OF DESALINATION: THE
CANARY ISLANDS EXPERIENCE
M. Hernandez Sudrez
Canary Islands Water Center
SPAIN
ccagua@retemail.es http://www.fcca.es
The Canary Islands Water Center is a foundation, created by the initiative of the Canary Islands
Government in 1998, with the support of the Water Councils of the seven islands of the
archipelago and several private companies working in the Canary Islands in the water related
subjects.
The first desalination plant (MSF type) was constructed in Lanzarote in 1964. Today, over 300
plants of different sizes, from 100 m3/day to 40 000 m3/day, produce more than 133 hm3/day
(32.5 mgd) of desalinated water. About 70 % of the feedwater is sea water, either from direct
intakes or from beach wells. The remaining feedwater is mostly brackish water from coastal
wells. Few plants desalinate also highly bicarbonated mountain water on the island of Tenerife.
Most of the plants (approx. 90 %) are reverse osmosis (RO) plants.
This presentation reviews some data in relation to brine discharge and feedwater intake, as well
as advances in the use of renewable energy for desalination and recent developments in energy
recovery devices for RO units.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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Figure 1. Total water use and desalination in the Canary Islands
Coastal effect of brine discharge and feedwater intake
Coastal effects of brine discharge and feedwater intake are analyzed from field data collected
near the coastal area of Maspalomas resort area. The desalination plant object of study produces
25 000 m3/day of desalinated water with an intake of 42 000 m3/day feedwater. The brine
discharge is 17 000 m3/day and has a TDS of 90 000 mg/L. It takes place by means of two
outfalls that lay parallel and close to each other. Both outfalls are 300 m long. The depth of the
brine discharge from the outfalls is 7.3 and 7.5 m respectively. The temperature of the brine is
2ฐC higher than ocean temperature.
The feedwater pipeline is 700 m long and lays 600 m east of the brine discharge points. The
depth of the intake is 11.3 m. Sixty six water samples were taken in a radius around the brine
discharge point covering an area of 1 km2. Salt concentration and temperature measured at
different depths allowed to pictured the isolines of the salt concentration in the area. Results
showed that brine discharge quickly dissolves into ocean water. Salinity decreased from +203 %
down to +0.04 %, above normal seawater concentration, within 20 meters from the discharge
point. Results appear also to indicate that the feedwater intake alters currents from deeper areas,
thus causing an increase in salinity around the intake of +0,02% to 0,04%. Visual inspection of
the seaweeds communities around the brine outfall and feedwater intake, showed no major
impact on the species living in that area.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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Figure 2. Desalination plants, outfalls and direct discharge points in Gran Canada island
R&D in renewable energy applied to desalination
Various projects are being carried out by several international research groups at the Canaries
Technological Institute (ITC) research station of Pozo Izquierdo in Gran Canada.
Studies financed by the EU, the Spanish Government and other Institutions are investigating the
use of wind and solar energy for desalination purpose.
An example of these studies is the SDAWES project (Seawater desalination by means of an
autonomous Wind Energy System) it consist of an off-grid wind farm (two wind generators with
230 kW nominal power each) supplying electricity to three different types of desalination
systems: Eight RO modules (each 25 m3/d); one 250 m3/d EDR plant (electrodyalisis reversible);
and one 50 m3/day VC plant (vapor compression). Results have allowed to understand the impact
of the oscillating wind power on the problems and management techniques to be considered for
operating each of this plants. The know-how of this project has allowed to develop a self
sustained RO unit (18 m3/d) driven by a commercial 15 kW wind generator and supported with
short-time battery storage.
SODESA is another internationally funded project, based on a solar thermally driven desalination
system with corrosion free collectors and a 24 hours per day storage. The installation consists of
a distillation system (based on a German patented multieffect humidification process) and driven
by low temperature heat produced in a high efficiency non-corrosive collectors, in which
seawater is heated directly without using an additional heat exchanger. The system operates at
ambient pressure and a temperature of about 80 ฐC and includes a hot seawater storage reservoir
that reduces thermal inertia losses and allows a 24 h/day distillate production.
Finally, a detailed feasibility study has been submitted to make the small island of El Hierro (269
km and 8 330 inhabitants) self sustainable in water and energy using a combination of wind and
hydraulic energy, in combination with RO desalination.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
OUTFALL
SWEET WATER
SEAWATER
INTAKE
Figure 3. Sizing RO plants for wind energy (CIEA-ITC et al., 1999)
R&D on isobaric chambers to recover pressure from the brine of RO units
Various developments in isobaric chambers have irrupted in the desalination market in the past
year allowing for a very efficient energy use in the RO plants. A system, called RO-Kinetics
developed in the Canaries by a local company, based on this principle, has shown also very good
results. It consists of two loops, that function alternatively, allowing for the continuous transfer of
pressure from the brine to the feedwater. The system has been under development for the past
two years. Tested on a 250 m3/day plant has given an energy consumption of 2.3 kW/m3
desalinated water. Recent developments in its design has make it a robust independent unit, ready
to been adapted to RO units of different sizes of up to 3 000 m3/d.
ENVIROMENTAL PROGRESS IN DOW CHEMICAL IBERICA
J. Bessa
Responsible Care leader. Dow Chemical Iberica, S.A.
SPAIN
jbessa@dow.com http://www.dow.com
At Dow, protecting people and the environment will be a part of everything we do and every
decision we make. Each employee has a responsibility in ensuring that our products and
operations meet applicable government or Dow standards, whichever is more stringent. Our goal
is to eliminate all injuries, prevent adverse environmental and health impacts, reduce wastes and
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emissions and promote resource conservation at every stage of the life cycle of our products. We
will report our progress and be responsive to the public.
2005 environment, health and safety goals
In 1995, Dow announced Environment, Health and Safety (EHS) goals for the Year 2005. These
are voluntary global goals and each geography has adopted them as a part of our commitment to
Environmental Progress following the Guiding Principles of Sustainable Development published
in early 2000.
These goals are categorized, as follows:
Responsibility and Accountability. Aggressively promote the Responsible Care
ethic by:
Fully implement Codes of Management Practices globally
Promote Responsible Care ethic among major associations, customers, suppliers and
policy makers
Incorporate principles of sustainable development and economic efficiency into
business strategies
Prevent Environment, Health and Safety Incidents. Significantly improve Dow's EHS
performance by reducing:
Injuries and illness per 200 000 hours by 90 %
LOPC (leaks, breaks, spills) by 90 %
Transportation incidents per 10 000 shipments by 90 %
Process safety incidents by 90 %
Motor vehicle incidents per 1 million miles by 50 %
Increase Resource Productivity. Further reduce air and water emissions for our operations:
Priority compounds by 75 %
Chemical emissions by 50 %
Amount of waste and waste water generated per pound of production by 50 %
Reduce energy use per pound of production by 20 %
CASE STUDY 1: Installation of Cyclone Scrubber Systems in our production trains of
polyethylene of Tarragona.
This project consisted of the installation of a cyclone scrubber system per train which was
designed to avoid molten polymer to be sent to the atmosphere when an emergency shutdown
occurs, as well as to reduce the noise level produced as a consequence of the reactor
depressurization. The design of the system was performed by MFC, according to a license
agreement with Dow. The system includes the following components: blow down vessel, venturi
spacer, cyclone separator and vent stack (Fig. 1).
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April 2002
LDPE
Low Density Polyethylene
Figure 1. LDPE process and cyclone scrubber system for the reduction of LOPC's events
Blow down vessel receives the gas vented during the shutdown of the plant and high pressure
steam is injected simultaneously to avoid potential plugging. Venturi spacer connects the blown
down vessel with the cyclone and is designed to allow the installation of a water injection.
Finally, cyclone separates the polymer from the gas and the vent stack allows the ethylene gas to
be exhausted to the atmosphere.
In addition to this installation, a project team at one of the trains was nominated to reduce the
number of above mentioned vents known as loss of primary containment. The team made
modifications in the process control program, improved some maintenance practices related to
electrical and mechanical items and developed a preventive program for the plant's
instrumentation involved in emergency shutdowns. Since then, LOPCs have been drastically
reduced and consequently plant reliability has improved.
CASE STUDY 2: Elimination of an existing solar pond used to hold wastewater of high
COD content generated in the polyols plant of Tarragona.
For some years, the effluent generated at the polyols plant was conveyed to a solar pond until a
strategic plan was established to empty the pond and return about 4000 m2 of land to its original
state.
The plan was carried out in three stages. Firstly, the effluent was minimized by using the MET
and following procedures stated in the operating discipline including internal recycle and disposal
of wastewater coming from the finishing section in the site boiler. Secondly, two evaporation
units were installed in order to reduce, as much as possible, the level of the pond. Thirdly, the
sludge mostly polyol and KOH was taken away by an authorized company for final disposal.
At present, the effluent generated is mostly treated internally by using only one evaporation unit
and about 10 % is treated externally. The pond has been demolished and the area returned to its
original state.
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LIGNOSULPHONATES: ENVIRONMENTAL FRIENDLY PRODUCTS
FROM A WASTE STREAM
M. Rodriguez andR. Peon
Lignotech Iberica S.A.
SPAIN
marino.rodriguez@borregaard.com
Black liquors, containing lignin, have been traditionally considered as a strong polluting stream
from pulp mills due to their high COD, dark persistent color and foaming tendency.
Kraft pulping introduced the combustion of the lignin to produce energy and recover chemicals.
However, a small purge of the digestion liquor, that is usually disposed of, is still needed to avoid
increasing concentrations of wood extractives.
Sulphite mills, where lignin combustion is not so easy due to SC>2 emissions, had to seek for a
different solution to this polluting stream to comply with stricter regulations.
Borregaard LignoTech, world leader in his business sector, has considered lignin from Spent
Sulphite Liquor as a renewable source of chemicals and developed different specific products for
several industrial applications.
Lignosulfonate derived products are now worldwide extensively used as concrete plasticizers,
providing better workability and increased strength with optimum cost/performance ratio.
In addition to this performance benefits, the use of lignosulfonate concrete admixtures provides
an additional environmental aspect in preventing global warming. Cement manufacturing is well
known for its contribution to the Greenhouse Effect (0.5-0.8 ton CCVton cement emitted).
LignoTech world sales in 2000 to concrete admixtures avoided the emission of about 5 million
tons of CC>2 to the atmosphere due to a 5 % reduction in the use of cement.
LignoTech products are also used in many other different areas, such as ceramics, carbon black,
particle and gypsum boards, animal feed binders, dye dispersing agents, oil well drillings, etc.
The use of membrane separation processes, have enabled the manufacture of better performing
products with a higher added value and also opened a new window in markets not formerly
considered.
Different studies have proved the feasibility of lignin as an alternative source for many chemicals
currently obtained from petroleum, but this development is still not economically viable.
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HYDROGEN ECONOMY AND FUEL CELLS: ENERGY FOR THE
FUTURE
M. A. Pena
Institute of Catalysis and Petrochemistry, CSIC
SPAIN
mapena@icp.csic.es http://www.icp.csic.es
The management of energetic sources and processes will require, in the near future, more
efficient and cleaner systems. This challenge should be faced under an innovative point of view,
changing the overall scheme of production, transformation, and use of the energy. Most of the
fuels used up to now derive from oil as starting material. This aspect has enormous
environmental implications in order to accomplish the level requirements in Europe and in the
USA. The use of Hydrogen as a clean energy vector, and the application of the Fuel Cells
technology, are two of the most proposing issues to be included in the new energetic scheme.
Besides, there is a clear tendency for the replacement of oil by natural gas as primary energy
source. In the proposed energetic layout discussed in this presentation, natural gas is converted in
a first step into hydrogen/syngas. The use, afterwards, of these energetic vectors require catalytic
technologies allowing the syngas transformation into clean liquid fuels. These can be used in
internal combustion engines (long chain hydrocarbons) or allowing the transformation of the
liquid fuel on the vehicle itself (short chain paraffins or methanol) into hydrogen that can be used
either by vehicles using fuel cells or internal combustion engines. Another way of envisage the
problem is using methanol directly to feed the fuel cell, which requires high efficiency
electrocatalysts keeping though the price low. The ensemble of the above-mentioned processes is
immerse into a global energetic scheme in which the environmental impact is reduced
enormously comparing with the current technologies. Increasing also the process efficiency and
overall yield allows keeping costs low and competitive. The development of efficient catalysts
together with catalytic technologies plays a very important role in these processes rising the
development level of a sustainable energy for the future.
THE USE OF MEMBRANE TECHNOLOGY IN PULP AND PAPER
INDUSTRY
D. Gomez, S. Luque, J. R. Alvarez and J. Coca
Department of Chemical & Environmental Engineering. University of Oviedo.
SPAIN
jras@sauron.quimica.uniovi.es http://www.uniovi.es/~ingenieria.quimica
The pulp and paper industry is one of largest consumers of water producing a wide variety of
effluents due to the different processes involved.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
The use of membrane technology at different places in order to provide end-of-pipe treatments or
water recycling opportunities has been carried out at the University of Oviedo in cooperation
with several industries from Asturias and close regions from the north of Spain.
Ultrafiltration and nanofiltration techniques have been applied to the bleaching effluents from an
Elemental Chlorine Free (ECF) bleaching process, as well as the general effluent coming from
the neutralization of acid and alkaline streams.
Ultrafiltration of black liquors and Spent sulphite liquors has been performed in order to obtain
lignin fractions suitable for higher value- added products.
Nanofiltration of the chelate stage in Total Chlorine Free (TCF) bleaching sequence have been
carried out in order to remove Iron and Manganese that are catalysts for the decomposition of the
hydrogen peroxide used.
TCF bleaching
Washing
Unbleached
(burnt or MWWTPi
Reuse in alher ocntian
of the pJnnl
Pulp
0V-1 SO
Process design
Irrd
JtlW m'.'h
4.* m'.'h
Staff* 1 ftgg* 2 StQQi 3
Mซmbronซ ซrซo |m*)
Wotvr recovery 1%)
ParmซaTa flux (L/h m'|
Pซrm*arซ Howrat* [mi/h|
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Microfiltration of different streams inside the pulp production process have been carried out in
order to eliminate the colloidal organic matter (pitch) in order to increase the quality of the
resulting pulp and to recycle the pitch as additional fuel to the main recovery boiler.
Nanofiltration and Reverse Osmosis of feed boiler water have been performed in order to
minimize the scaling problems.
ACTIVITIES AND INITIATIVES TO SUPPORT COMPANIES AND
BUSINESS SECTORS TO IMPROVE THEIR RELATIONSHIP WITH THE
ENVIRONMENT
B. Gattego
Centre for the Companies and the Environment. Ministry of the Environment of the Government
of Catalonia
SPAIN
prodneta@cema-sa.org http://www.cema-sa.org
The Centre per a I'Empresa i el Medi Ambient (CEMA) is a tool of the Ministry of the
Environment of the Government of Catalonia at the companies' service, that focuses its attention
on promoting Cleaner Production among industry sectors and companies.
In seven years of activity, the CEMA has developed initiatives and activities that have turned out
to be a significant support for companies as regards their relation with the environment.
Among these activities, the assessment done to companies in their search for cleaner technologies
and experts, the participation in training and diffusion activities, the organization of Cleaner
Production diffusion campaigns and the elaboration of studies and publications to promote
Cleaner Production are some examples.
Also, CEMA monitors and supervises the carrying out of the Minimization Opportunities
Environmental Diagnosis (tool promoted by CEMA that consists on the assessment of an
industrial activity to detect potential CP opportunities, and for providing the business with
sufficient data for it to orientate its policy towards cleaner practices and technology that are
technically and economically viable) and Work Groups (tool aimed at studying the alternatives
for the reduction of pollution at source in an industrial sector or geographical area).
Achievements in our aim of promoting Cleaner Production among industry sectors and
companies include the following:
More than 250 Catalan companies have implemented a Minimization Opportunities
Environmental Diagnosis. Based on a sample of companies, the identified pollution
prevention options by means of the MOED have made possible a 26 % reduction in water
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
consumption, 14 % reduction in consumption of raw materials, a 29 % reduction in waste
waters and a 23 % reduction in solid waste generation.
8 Work Groups have been carried out, with a participation of a total of 61 companies of
the following industry sectors: surface treatment, textile, painting, printing and
metallurgy.
The CEMA has a database of cleaner technologies (with more than 240 inputs) and
suppliers of environmental goods and services (with more than 500 inputs) to assess
companies. As an example of the assessment done to companies, in 2000, more than 600
consultations were met.
A pilot diffusion campaign aimed to promote Good Housekeeping practices was carried
out with 8 participating companies (in the food, chemical and printing industries and in a
hotel) and 75 staff training sessions.
The CEMA has co-operated in four demo projects to verify, within a technical and
economic feasible framework, practices and technologies to prevent pollution applied to
companies on a real scale.
More than 15 studies have been carried out by the CEMA, and 56 files showing examples
of waste minimization opportunities implemented in companies and more than 50 articles
in technical and economic magazines have been published.
The CEMA has participated in more then 200 seminars, courses, etc to promote and
diffuse the principles and advantages of Cleaner Production.
In addition, due to the Collaboration Agreement signed between the Spanish and Catalan
Ministry of the Environment, the CEMA carries out a whole lot of activities within the
framework of the United Nations Mediterranean Action Plan as Regional Activity Centre for
Cleaner Production (RAC/CP) and it also participates in International Projects and develops co-
operation activities in Latin America with the objective of further promoting Cleaner Production.
The initial scenario encountered when dealing with companies was characterized by a passive-do
nothing- approach that became reactive: adopting corrective actions in front of legislative
pressure- and then active: adopting corrective actions before having sanctions without
considering the environment as a change opportunity.
The CEMA aims at achieving a step further: the proactive approach, where the environmental
management orientated towards CP is integrated in the global company management and the
company adopts a continuous improvement strategy.
In acknowledgement of its aims and proactive initiatives with companies, the CEMA has been
awarded the "in Prize Company and Environment" within the "Best Public Support Initiative for
Companies" by the most-widely spread newspaper in Spain, Expansion, the Garrigues-Arthur
Andersen consulting group and the Institut d'Estudis Superiors de I'Empresa (IESE), given on
October 3rd by the Minister of the Environment.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
TREATMENT OF OIL-CONTAINING WASTEWATERS USING CLEAN
TECHNOLOGIES
J. M. Benito, G. Rios, E. Ortea, E. Fernandez, A. Cambiella, C. Pazos and J. Coca
Department of Chemical & Environmental Engineering. University of Oviedo.
SPAIN
jcp@sauron.quimica.uniovi.es http://www.uniovi.es/~ingenieria.quimica
Oil-in-water emulsions are found in several industrial operations involving two inmiscible fluids.
Some of them are desirable (e.g. as final products in the cosmetics and food industry), but in
some cases they are undesirable, as in liquid-liquid extraction operations, removal of rubber from
latex, cleaning bilge water from ships, cold rolling mill effluents, etc. Spent cutting-oil emulsions
are one of the largest volumes of oily wastewaters resulting from metalworking industries,
specially in steel cold rolling operations. Water-based lubricants and cutting oils have replaced
some petroleum-based products in the metalworking industry, as a result of their higher
performance. These fluids, containing mainly emulsified oil and surfactants which allow
emulsion formation and stabilization when mixed with water, become less effective after use
because of their thermal degradation and contamination by substances in suspension, and
therefore they must be replaced periodically. The spent oil must be treated before its disposal, due
to their detrimental effects on aquatic life and their interference with conventional wastewater
treatment processes. Several physicochemical methods for the treatment of spent oils, such as
settling, chemical treatment, dissolved air flotation, centrifugation and membrane techniques
have been investigated.
The aim of this work is the design and construction of a modular pilot plant for the treatment of
different water-based coolants and oily wastewaters generated in metalworking processes and
steel cold rolling operations. A suitable spent cutting-oils treatment consists of three basic steps:
primary, secondary and tertiary treatment, as shown in Fig. 1.
The design should allow the combination of several treatment operations, depending on the
nature of the stream to be treated. The entire process should be automatically controlled using a
specific computer software. Different treatments will be considered depending on the nature of
the oily waste emulsion, such as coagulation/flocculation, centrifugation, ultrafiltration and
sorption processes. With these principles in mind a modular plant was built and its schematic
diagram is shown in Fig. 2.
The main advantage of this plant is its versatility, allowing the combination of the
aforementioned treatments, being a feasible waste management alternative from an economic
point of view. This might lead to a better control of this kind of wastes and a better reuse of
water, in the case of large industrial plants, with the resulting environmental and economic
improvements.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
April 2002
REGENERATION
- COMBUSTION
- DESTRUCTION
OILY
WASTEWATER
DISPOSAL RECYCLING
RECOVERY DEHYDRATION
Figure 1. General process for the treatment of spent cutting oils
FUTBKTfiMA I PBฃTRฃi.Trฃ -11
MODULE t? 1
M
,
n Q - -
fl
M *
MODULE
MODULE ff 3
Figure 2. Schematic diagram of the modular pilot plant for the treatment of oil-containing
wastewaters
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
THE NEW LEGISLATION ON ENVIRONMENTAL QUALITY AND
CLEAN PRODUCTION
J. Martinez
Ministry of Environment
SPAIN
Juan.martinez@sgca.mma.es http://www.mma.es
A brief summary will be reported on the recent legislation (Spanish and European) regarding
environmental quality and its relation to the European Directive 96/6I/EC on Integrated
Prevention and Control of Environmental Pollution (IPPC).
NON-FERROUS METALLURGICAL WASTES: FUTURE
REQUIREMENTS
J. M. Poncet
Asturiana de Zinc, S.A.
SPAIN
http://www.azsa.es
The deterioration of environmental quality, which began when man first collected into villages
and utilized fire, has existed as a serious problem under the even-increasing impact of
exponentially increasing population and of industrializing society. As a consequence of that there
are an uncontrolled and increasing generation of waste, resulting a environmental contamination
of air, water, soil and food.
The challenge of our society is to find the equilibrium between development and environmental
protection, in order to reach a sustainable development: the way of satisfying the needs of the
modern society without an irreversible damage of the natural resources. Two tools could be used:
Best Available Techniques (BAT): the latest stage of development (state of the art), of
processes, of facilities or of methods of operation which indicate the practical suitability
of a particular measure for limiting discharges, emissions and waste.
Best Environmental Practice (BEP): the application of the most appropriate combination
of environmental control measures and strategies.
The aim of this research is the application of these tools for the treatment of wastes generated in
non-ferrous (pyrometallurgical, hydrometallurgical and melting) metallurgical operations:
Waste for recovery: those that can be recycled or reused either in the same plant where
they were generated, or in other plant in a different location.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Waste for disposal: those that, with the present state of the art, cannot be recycled or
reused. This type of residue can be generated by a primary metallurgical process or as a
consequence of waste recycling.
The Principle: The environment is an additional responsibility of the company that must be an
integral part of the company's management.
HOW TO MAKE CARBOCHEMISTRY COMPATIBLE WITH THE
ENVIRONMENT
J. J. Fernandez and I. Trettes
Department of R&D. Industrial Quimica del Nalon, S.A.
SPAIN
juanjo@nalonchem.com http://www.nalonchem.com
It is very well known that carbochemistry is considered worldwide as a very pollutant activity. In
this paper it is shown how Industrial Quimica del Nalon, S.A. manages its plants and
environmental policy to meet the clean processes criteria.
Industrial Quimica del Nalon, S.A. was founded in 1943 with the explicit vocation of developing,
manufacturing and marketing chemical products, with a especial orientation towards coal and its
derivatives.
Located in Asturias (Spain), its industrial activity started in Trubia with the distillation of coal tar
and the manufacture of the inorganic salts of potassium (nitrate and permanganate), lead and
calcium, continuing in 1945 with the manufacture of foundry coke and the treatment of by-
products, obtaining ammonium sulphate and benzol. With the passing of time, numerous
economic cycles and technological changes have taken place that have meant the reorganisation
of its different industrial activities and work centres.
Currently, the company develops its corporate activity along two lines of business: High
specification carbochemical products and coke, being the most important private distiller of tar
and one of the leading producers of foundry coke in Southern Europe.
Its centres of production in Asturias, based in Trubia (Carbochemicals Division) and Langreo
(Coke Division), have logistics installations in the ports of Aviles (Spain), Szczecin (Poland) and
Marseille (France). Its head office is located in Oviedo (Spain).
Its business trajectory is founded under the attributes of corporate solvency, development of its
own technological processes, respect for the environment, differential quality in products and
services, safety and health of its employees, collaborators and the surrounding environment.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
The development of these attributes of business excellence has led Industrial Quimica del Nalon,
S.A. to the technological forefront in the field of Carbochemicals and to be the first European
company to certify its Quality and Environmental Management system on the basis of the
requirements of the ISO 9002 and ISO 14001 standards, respectively.
Environmental policy
"In the development of industrial activity, behavior that affects the safety and health of our
employees, neighbours, customers and the community in general, and respect for the
environment, will be of priority interest in business decisions".
Industrial Quimica del Nalon, S.A., considers respect for the environment as an strategic,
competitive factor and a permanent and priority element of its activities.
The basic directives of this policy with respect to the environment are: Compliance with the legal
regulations in force, training and information for employees, information to the authorities,
neighbours and the community in general, collaboration with the competent Administrations and
Institutions (voluntary agreements), continuous improvement of processes and products,
minimizing and anticipating negative environmental effects, rational use of natural resources,
prevention and control of pollution by means of documented procedures and, collaboration with
and information to suppliers and customers.
During the period 1993-2000, a series of actions have been taken with the aim of integrating the
Environment into the productive processes and management of the Company, not only as a legal
requirement, but also as a factor of competitiveness that enables the conquest of new markets, an
improvement in sales and the consolidation of the Company's leadership.
The aim is, therefore, to adequately manage the environmental aspects of our activities in order to
transform the Environment into a differential, strategic factor, which will itself increase external
credibility with respect to customers, the Administration and our environs.
The fundamental lines of action have been: Direct (environmental correction) or indirect (new
plants) investment plans and the development of an environmental management system in
accordance with the requirements of the ISO-14001 standard.
Investments are oriented towards reducing atmospheric emissions, residues and noise, as well as
towards new facilities. These investments have meant:
The employment of the best available technologies in the new plants built
The definitive authorisation on the part of the Administration for the emission of liquid
effluents at the sites at Trubia and Ciafio
A substantial reduction in specific energy consumptions and, therefore, in the
corresponding emissions
The substitution of fuels with a high sulfur content (2.5 %) by others with a lower
content (0.7 %), with the subsequent reduction in SO2 emissions
Recovery and re-utilization of carbon residues from surface water ponds
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
Rational use of natural resources (water and energy)
Elimination of un-controlled emissions
An example of a clean, carbochemical process: production of refined naphtalene
Technical grade naphthalene (96.5 %) is obtained directly from tar distillation. Its major
contaminants are sulfur (present as thionaphthene) and phenols that have boiling points too close
to naphthalene.
For catalytic processes, sulfur compounds can poison the catalyst, decreasing its operating life
and efficiency. For domestic, colorants, and leather applications phenols make the colour
unstable.
By a selective catalytic hydro treatment sulfur (present at a level of 5 000 ppm) is transformed
into hydrogen sulfide that is very easy to remove. Final sulfur content could be as low as 2 ppm.
Hydrogen sulfide is washed with sodium hydroxide to produce a sodium sulfide solution suitable
for water treatment plants as a precipitant for heavy metals, leather pre-treatment and mineral
flotation.
Before the hydro treatment stage, naphthalene is hot washed with a sodium hydroxide solution to
extract phenols, producing a sodium phenolate solution that is marketed for phenols recovery.
These phenols are used as biocides and for fine chemicals manufacturing in general.
Other suitable processes for naphthalene purification involve dynamic or static crystallization
stages that yield a heavy contaminated oil. There is no application in the market for such a kind
of oil due to its high sulphur content. The only possibility is to use it as a fuel, but it makes SC>2
emissions to be out of the control limits.
Hydro treatment processes in combination with liquid and gas/liquid extraction allows Industrial
Quimica del Nalon to produce the highest purity naphthalene in the market (>99.97 %) with
absolutely no effluents and no solid residues.
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
TREATMENT OF PHENOLIC WASTEWATER IN THE SALICYLIC
ACID MANUFACTURING PROCESS
M. F. Ortega, A. Cagigas and J. Alvarez
Quimica Farmaceutica Bayer, S.A
SPAIN
jorgejulian.alvarezrodriguez.ja@bayer.es
Many chemical processes generate wastewater streams containing high concentrations of organic
materials. Phenols are one of these materials and are difficult to be treated by conventional
methods. Wastewater of salicylic acid manufacturing process has phenol and several phenolic
compounds, a pH of 2 and a high concentration of sulfate ions, which must be decreased before
being pumped to the local wastewater treatment plant.
In this work, it is studied the elimination of the phenol content in the effluent by means of
LOPROX process (Low Pressure Oxidation). This is a wet air oxidation method, developed by
Bayer AG. It is also studied the reduction of sulfate concentration by means of recovery as a
calcium sulfate after precipitation with calcium hydroxide. Calcium sulfate can be reused by
cement industry.
Experimental
This study has been carried out in LOPROX plant of Quimica Farmaceutica Bayer, S. A (La
Felguera Factory). Figure 1 shows a flow diagram of LOPROX plant.
Phenolic wastewater is pumped (12 - 14 bar) to first column (B2a), after being preheated with the
outlet stream in heat exchangers (Wl.l, W1.2 and W1.3). In the first column it is also introduced
a stoichiometric amount of oxygen through an injector (!A). There, fine bubbles are formed,
improving the contact between gas and liquid. Oxidation is an exothermic reaction, but it is
necessary to heat with steam in order to reach 140 ฐC.
Column B2a works completely full and the outlet stream is pumped to the second column (B2b),
where an additional amount of oxygen is added (Injector IB). This column has a level measuring
device (B2c). The outlet liquid stream flows from the bottom of B2c to storage vessel. The outlet
gas is released in the top of column, where is also controlled the pressure of the system at 10 bar.
Oxidation reaction is catalyzed by Fe++. Catalyst is prepared from FeSO4x7FL:O and is pumped to
B2a Column. Following reactions occur:
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I)
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2 Fe2+ + 1/2 O,
sJHydrochinon
- 2 Fe3+ + O2"
O
OH
H2O2+Fe2+
RH + HO'
RH + HO2-
R' * O2
O
p-Benzochinon
H202
FeJ+ + HO- + OHT
. H2O + R-
- H2O2+ R'
ROO- ^-R^COO--
OH
. y F03+
- R, + CO,
Figure 1. Flow diagram of LOPROX process
Results and discussion
Figure 2 shows the inlet phenol concentration and the outlet phenol concentration for a certain
number of samples. The final concentration of phenol is always less than 2 ppm. The COD
reduction can be observed in Figure 3. The outlet wastewater (after LOPROX treatment) has a
ratio COD:BOD < 2:1. Therefore, it is a biodegradable stream. The reduction of salicylic acid
(S.A) concentration is over 95 %.
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1800
E 1500 -
a 1200 - -
3 900 -
% 600 -
PH 300 -
0
-S.A (inlet) S.A (outlet) ACOD (inlet) ICOD (outlet)
0 2 4 6 8 10 12 14 16 18 20 22
Sample number (years 99 - 00)
Figure 2. Degradation of phenol
Figure 3. Salicylic acid and COD evolution
The outlet stream of LOPROX process has a pH of 2. Neutralisation can be carried out with
calcium hydroxide. Depending on the final pH, a certain amount of calcium sulphate can be
precipitated. Figure 4 shows that for a pH of 7, a decrease of 70 % of the initial sulphate
concentration (50 g/1) can be obtained, which means 63 g/1 of precipitated calcium sulphate
(gypsum, CaSO4x2H2O). This material can be used in cement industry.
10 20 30
Sulfate (g/l)
40
Figure 4. Sulphate concentration vs pH
Conclusions
LOPROX procedure is an adequate method for the elimination of phenol content of the phenolic
wastewater stream, generated in manufacture of salicylic acid. There is also a strong decrease in
COD. Neutralisation of the outlet stream, under appropriate conditions, produce calcium sulphate
as a recovered material.
References
1. Otto Horak, Chem.-Ing.-Tech. 62, 7, 555-557 (1990)
2. Bayer AG, Geschaftsbereich SN, Umweltschutztechnik D-5090 Leverkusen
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NATO FIELD TRIPS
The traditional field trip was held on Wednesday, May 9, 2001. Meeting participants were given
a tour of the Department of Chemical Engineering at the University of Oviedo. Several
laboratories and pilot plant facility were included in the tour. The field trip continued with a visit
to the DuPont Company facility. A tour of the NOMEX production facility and its ecosystem
restoration projects highlighted the visit. The technical tours were interrupted to visit the scenic
coast of Asturias and its impressive cliffs. The field trip concluded with a tour of a cider
production plant in Villaviciosa.
DuPont Asturias Plant
The DuPont plant in Asturias began its activities in 1993. Currently the plant produces
Tetrahydrofuran (THF), Nomexฎ brand fiber and Sontaraฎ spunlaced products. Nomex is a fiber
used in fabrics for apparel, ranging to men's suits.
DuPont invested $100 million to expand the capacity to produce this elastane fiber at the
Maydown Plant. DuPont's Kevlar brand fiber provides a unique combination of toughness, extra-
high tenacity and modulus, and exceptional thermal stability, Applications for Kevlar include cut,
heat, and bullet/fragment resistant apparel; brake and transmission friction parts; and sporting
goods.
The NATO/CCMS Pilot Study group at DuPont plant
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Valle, Ballina y Fernandez
The Valle, Ballina y Fernandez is one of the oldest cider companies in Spain. It is located on the
edge of the town of Villaviciosa, one and a half hour drive from Oviedo. This company makes
cider from the Asturian apples, although it needs to purchase apples from other regions in Spain,
and even from some European countries. The company uses modern technology, including
several membrane processes, and it was the industrial partner in a European project, in order to
study the depectination of apple using enzymes and the recovery of aroma compounds by
pervaporation.
The main cider brand produced in the company is "Sidra El Gaitero" which is very popular in
Spain, South America and Florida (US), because of the large number of Cuban population in that
state.
At the end of the tour the participants had a chance to taste several kinds of cider and a variety of
Asturian food specialties.
The group tasting the Asturian "Sidra El Gaitero " at the Valle, Ballina y Fernandez company
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NATO/CCMS Pilot Study on Clean Products and Processes (Phase I) April 2002
OPEN FORUM ON CLEAN PRODUCTS AND PROCESSES AND FUTURE
DIRECTION OF THE PILOT STUDY
The closing session of the meeting was held on Friday, May 11, 2001. Several issues were
discussed, but most discussion centered around the creation on new, multi-national pilot projects
that would move the pilot study into new areas. Several new pilot projects were identified for
initiation during the coming year. The following projects will begin during 2001:
Cleaner Production Approaches in Industrial Parks/Industrial Symbiosis/Industrial
Ecology - Denmark, Hungary, Israel, Poland and Turkey
Hybrid Membrane Applications for Cleaner Production - Denmark, Italy, Poland, Russia
and Spain
Sustainable Indicators/Bench Marking - Germany, Hungary, Lithuania and Norway
Cleaner Production Tools Application - Greece, Hungary, Lithuania and United States
The final order of business was the selection of the host country for the 2002 meeting. After
nominations and discussions, the delegates unanimously selected Lithuania to host next year's
meeting. Professor Jurgis Staniskis, Institute of Environmental Engineering, Kaunas University
of Technology, will host the pilot study's next meeting. The meeting will be held in Vilnius,
Lithuania, on May 12-16, 2002.
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APPENDIX I
LIST OF DELEGATES AND PARTICIPANTS
BULGARIA
Dr. Stefka Tepavitcharova. Delegate
Bulgarian Academy of Sciences. Institute of General and Inorganic
Chemistry
Acad. Georgy Bontchev Str., bl. 11
Sofia, 1113. BULGARIA
Telephone: +359 2 979 39 25 / Fax: +359 2 705 024
stepav@svr.igic.bas.bg
CZECH REPUBLIC
Ms. Dagmar Sucharovova. Delegate
Head of Unit for Strategy and Sectorial Policy
Department of Strategies and Environmental Statistics
Ministry of the Environment
Vrsovicka65 100 lOProague 10. CZECH REPUBLIC
Telephone: 420-2-730-746 /Fax: 420-2-6731-0340
Sucharovova_dagmar@env.cz
Col. Ales Komar. Invited Speaker
Military University
VitaNejedlehoS
Vyskov, 682 03. CZECH REPUBLIC
Telephone: 00 420 507 39 25 27 / Fax: 00 420 507 39 23 25
Komar@vvs-pv.cz
Dr. Frantisek Bozek. Invited Speaker
Military University
VitaNejedlehoS
Vyskov, 682 03. CZECH REPUBLIC
Telephone: 00 420 507 39 24 71 / Fax: 00 420 507 39 20 09
bozek@feos.vvs-pv.cz
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DENMARK
Associate Prof. Henrik Wenzel. Delegate
Department of Manufacturing Engineering and Institute for Product
Development. Technical University of Denmark
Building 424, 1st Floor. Room 117
Lyngby, DK-2800. DENMARK
Telephone: +45 4525 4663 /Fax: +45 4593 5556
wenzel@ipt.dtu.dk / http://www.ipt.dtu.dk
GERMANY
Dr. Horst Pohle. Delegate
Federal Environmental Agency
Bismarckplatz 1
Berlin, 14193. GERMANY
Telephone: ++49/30/8903-3374 /Fax: ++49/30/8903-3105
horst.pohle@uba.de / http://www.umweltbundesamt.de
GREECE
Dr. George P. Gallios. Delegate
Aristotle University of Thessaloniki. Department of Chemistry
Thessaloniki, GR-540 06. GREECE
Telephone: +30 31 99 77 16 / Fax: +30 31 99 77 59
gallios@chem.auth.gr / www.chem.auth.gr
Mr. Gyula Zilahy. Delegate
Hungarian Cleaner Production Centre
University of Economic Sciences and Public Administration
8, Fovam Ter
Budapest, H-1093. HUNGARY
Telephone: +36 1 215 5808 /Fax: +36 1 215 5808
zilahy@enviro.bke.hu / http://hcpc.bke.hu
ISRAEL
Prof. David Wolf. Invited Speaker
Ben-Gurion University of the Negev
P.O. Box 1025
Beer-Sheva, 84110. ISRAEL
Telephone: +972 7 130446 /Fax: +972 7 271612
dwolf@bgumail.bgu.ac.il
HUNGARY
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ITALY
LITHUANIA
Prof. Chaim Forgacs. Delegate
Ben-Gun on University of the Negev
P.O. Box 653
Beer-Sheva, 84105. ISRAEL
Telephone: +972 8 6280746 / Fax: +972 8 647784
forgacs@bgumail.bgu.ac.il / http://www.bgu.ac.il/IAR/Forgacs.htm
Prof. Enrico Drioli. Delegate
Department of Chemical and Materials Engineering. University of
Calabria
Via P. Bucci, I
Rende (CS), 87030. ITALY
Telephone: +39 0984 402706 /Fax: +39 0984 402103 or 492058
e.drioli@unical.it / http://www.unical.it
Prof. Jurgis Kazimieras Staniskis. Delegate
Institute of Environmental Engineering (APINI). Kaunas University of
Technology
Kaunas LT-3000. LITHUANIA
Telephone: +370 7 323955 /Fax: +370 7 209372
jurgis.staniskis@apini.ktu.lt / http://www.ktu.lt/apini
Mr. Sergiu Galitchi. Delegate
Operative Information Systems and Monitoring. State Ecological
Inspection. Ministry of Environment and Territorial Development
73, Stefan eel Mare
Chishinau, MD2060. MOLDOVA
Telephone: +373 2 242115 /Fax: +373 2 769130
sergiu@mediu.moldova.md
Dr. Annik Magerholm Fet. Delegate
Department of Industrial Economics and Technology Management.
Norwegian University of Science and Technology - NTNU
Trondheim, N-7491. NORWAY
Telephone: + 47 73 59 35 09 / Fax: + 47 73 59 31 07
Annik.Fet@iot.ntnu.no / http://www.iot.ntnu.no/~fet
MOLDOVA
NORWAY
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POLAND
Dr. Andrzej Doniec. Delegate
Pollution Prevention Center at the Technical University of Lodz
Ul. Stefanowski ego 4/10
Lodz, 90-924. POLAND
Telephone: +48 42 631 37 03 /Fax: +48 42 636 52 85
andoniec@ck-sg.p.lodz.pl / http://www.plodz.pl
PORTUGAL
Prof. Susete Martins Dias. Delegate
Institute Superior Tecnico. Centre de Engenharia Biologica e Quimica
Av. Rovisco Pais
Lisboa, 1049-001. PORTUGAL
Telephone: +351 1 8419074/Fax: +351 1 8419062
pcsdias@alfa.ist.utl.pt / http://dequim.ist.utl.pt
Dr. Teresa Mata. NATO Fellow
LEPAE - Laboratory of Processes, Environment and Energy
Engineering. Chemical Engineering Department. Faculty of Engineering
of Porto
Rua Roberto Frias
Porto, 4200-465. PORTUGAL
Telephone: +351 223326154
amartins@fe.up.pt
ROMANIA
Mr. Viorel Harceag. Delegate
FBCR - Maunsell
321, Calea Calarasi, bl. 202, sc. 1, ap. 17
Bucarest, Sector 3. ROMANIA
Telephone: + 401 3265651 /Fax: +401 3210018
viorelH(S)k.ro
RUSSIA
Prof. Gueorgui G. Kagramanov. Invited Speaker
Moscow Mendeleyev University of Chemical Technology of Russia
Miusskaya pi., 9
Moscow, 125047. RUSSIA
Telephone: 7 (095) 978 82 60 / Fax: 7 (095) 978 82 60
kadri@muctr.edu.ru / http://www.muctr.edu.ru
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SLOVENIA
Prof. Dr. Peter Glavic. Delegate
University of Maribor. Faculty of Chemistry and Chemical Engineering
Smetanova 17
Maribor, SI-2000. SLOVENIA
Telephone: +386 2 229 44 51 /Fax: +386 2 252 77 74
glavic@uni-mb.si / http://atom.uni-mb.si
Prof. Jose Coca Prados. Delegate
Department of Chemical and Environmental Engineering.
University of Oviedo
Julian Claveria, 8
E-33006 Oviedo. SPAIN
Telephone: +34 985 10 3443 /Fax: +34 985 10 3443
Jcp@sauron.quimica.uniovi.es / www.uniovi.es/~ingenieria.quimica
SPAIN
&l
Assistant Prof. Jose R. Alvarez. Invited Speaker
Department of Chemical and Environmental Engineering.
University of Oviedo
Julian Claveria, 8
E-33006 Oviedo. SPAIN
Telephone: +34 985 10 3028 /Fax: +34 985 10 3443
Jras@sauron.quimica.uniovi.es / www.uniovi.es/~ingenieria.quimica
Mr. Jordi Bessa, RCLeader. Invited Speaker
Dow Chemical Iberica. S.A.
Cerro de Castafiar, 72 B. Plantas 4 y 5a
E-28034 Tarragona. SPAIN
Telephone: +34 977-559354 / Fax: +34 977-559353
Jbessa@dow.com
Dr. Manuel Hernandez Suarez. Invited Speaker
Canary Islands Water Center
Castillo, 40. 1ฐ
E-38003 Santa Cruz de Tenerife. SPAIN
Telephone: +34 922-298664 / Fax: +34 922-296005
Mhs@retemail.es
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Dr. Miguel A. Pefia. Invited Speaker
Institute of Catalysis and Petrochemistry, CSIC
Campus Cantoblanco
Cantoblanco
E-28049 Madrid. SPAIN
Telephone: + 34-915 854 788 / Fax: +34 - 915 854 760
Mapena@icp.csic.es / http://www.icp.csic.es/
Dr. Juan J. Fernandez. Invited Speaker
Industrial Quimica del Nalon, S.A.
Avenida de Galicia, 31. Bajo
E-33005 Oviedo. SPAIN
Telephone: + 34 - 985 24 06 94 / Fax: +34 - 985 25 87 66
j uanj o@nal onchem. com
Ms. Belen Gallego. Invited Speaker
Centre for the Companies and the Environment
Ministry of the Environment of the Government of Catalonia
Paris, 184
E-08036 Barcelona. SPAIN
Telephone: +34 93 415 11 12/Fax (+34) 93 237 02 86
prodneta@cema-sa.org / http://www.cema-sa.org
Mr. Juan Martinez Sanchez. Invited Speaker
Ministry of Environment
Plaza de San Juan de la Cruz s/n
E-28071 Madrid. SPAIN
Telephone: +34 915 97 60 00 /Fax: + 34 915 97 58 57
Juan.martinez@sgca.mma.es
Dr. Jorge J. Alvarez. Invited Speaker
Quimica Farmaceutica Bayer, S.A.
P.O. Box 4
E-33930 La Felguera. SPAIN
Telephone: /Fax: +34 985 67 81 42
jorgejulian.alvarezrodriguez.ja@bayer.es
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TURKEY
UKRAINE
Prof. Aysel Atymtay. Delegate
Middle East Technical University. Environment Engineering Department
Inonu Bulvari
Ankara, 06531. TURKEY
Telephone: +90 312 210 58 79 /Fax: +90 312 210 12 60
aatimtay@metu.edu.tr
Prof. William M. Zadorsky. Delegate
Ukrainian State University of Chemical Engineering
Flat 23, home 41/43, Komsomolskaya str.
Dnepropetrovsk, 49000. UKRAINE
Telephone: +380 562 470813 /Fax: +380 562 470813
zadorsky@hotmail.com / http://www.zadorsky.8m.com
UNITED KINGDOM
Prof. Jim Swindall QBE. Delegate
QUESTOR Center. Queen's University
David Keir Building. Stranmillis Road
Belfast, BT9 SAG. Northern Ireland, UK
Telephone: +44 28 9033 5577 /Fax: +44 28 9066 1462
j.swindall@qub.ac.uk / http://questor.qub.ac.uk
UNITED STATES OF AMERICA
Dr. Subhas K. Sikdar. Director of the Pilot Study
National Risk Management Research Laboratory. Office of Research and
Development. United States Environmental Protection Agency
26 W. Martin L. King Drive (MS-497)
Cincinnati, OH, 45268. USA
Telephone: +1 513 569 7528 /Fax: +1 513 569 7787
sikdar.subhas@epamail.epa.gov / www.epa.gov/ORD/NRMRL/std
Mr. Daniel J. Murray. Co-Director of the Pilot Study
U.S. Environmental Protection Agency. Office of Research and
Development. National Risk Management Research Laboratory.
26 West Martin Luther King Drive (MS-G75)
Cincinnati, Ohio, OH 45268. USA
Telephone:+1 513 569 7522/Fax:+1 513 5697585
murray.dan@epamail.epa.gov / www.epa.gov/ttbnrmrl
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April 2002
Prof. Michael Overcash. NATO Fellow
North Carolina State University. Department of Chemical Engineering
HSRiddick. P.O. Box 7905
Raleigh, NC 27695. US A
Telephone: +1 919 515 2325 /Fax: +1 919 515 3465
overcash@eos.ncsu.edu / www.che.ncsu.edu/faculty_staff/mro3.html
Prof. Farhang Shadman. Invited Speaker
University of Arizona
Chemical Engineering Department. University of Arizona
Tucson, Arizona, 85721. USA
Telephone: +1 520 621 6051 /Fax: +1 520 626 5397
shadman@erc.arizona.edu / www.erc.arizona.edu
Associate Prof. Tillman Gerngross. Invited Speaker
Thayer School of Engineering. Dartmouth College
Hanover, NH 03755. USA
Telephone: 603-646-3161 /Fax: 603-646-2277
tillman.gerngross@dartmouth.edu /
thayer.dartmouth.edu/thayer/faculty/tillmangerngross.html
Thomas W. Chapman, Invited Speaker
Director of the Separation and Purification Processes Program
National Science Foundation. Interfacial, Transport, and Separation
Processes Program. Division of Chemical and Transport Systems (CTS)
4201 Wilson Blvd., Ste. 525
Arlington, VA, 22230. USA
Telephone: +1 703 292 7036 /Fax: +1 202 292 9054
tchapman@nsf.gov / http://www.eng.nsf.gov/cts
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APPENDIX II
PROGRAM FOR THE MEETING IN OVIEDO, SPAIN 2001
SUNDAY, MAY 6, 2001
18:00 Participants gather in the Hotel Ramiro I
18:30 Reception, registration and get-together at Hotel Ramiro I
Welcome:
Dr. Subhas K. Sikdar, Pilot Study Director
U.S. Environmental Protection Agency
National Risk Management Research Laboratory
Cincinnati, Ohio, USA
Prof. Jose Coca
Department of Chemical and Environmental Engineering
University of Oviedo
Oviedo, Spain
20:00 Departure for Dinner (Bus)
20:30 Dinner at Latores Restaurant
MONDAY, MAY 7, 2001
08:15 Breakfast-Hotel Ramiro I
09:00 Welcome-Oviedo Auditorium. R Gutierrez Palacios, General Director of Universities, Higher Education andResearch andJ.
A. Vazquez, Rector of the University of Oviedo
09:15 Meeting Introduction. S. K. Sikdar, Pilot Study Director
09:30 Introduction round of country delegates and participants
09:45 Overview of Meeting Agenda, Field Visits and Events. D. Murray, Pilot Study Co-Director
10:00 Break - Coffee/Tea
10:30 Presentation (30 min)
HOW GREEN ARE GREEN PLASTICS?. T. Gemgross (USA)
11:00 Pilot Project Updates (20 min each)
TOOLS FOR POLLUTION PREVENTION. S. K. Sikdar (USA)
ENVIRONMENTAL IMPACTS OF HC EMISSIONS IN LIFE CYCLE ANALYSIS OF GASOLINE BLENDING
OPTIONS, T. M. Mata, R. L. Smith, D. M. Young, and C. A. V. Costa (Portugal-USA)
PILOT STUDY WEB SITE. D. Murray
12:00 Departure for visit of the Down Town (walking distance from the conference centre)
12:45 Welcome by Oviedo Major Gabino de Lorenzo. Oviedo City Hall.
13:00 Lunch
14:40 Arrival-Oviedo Auditorium
15:00 Tour de Table Presentations (15 min each)
PROGRESS AND NEW PERSPECTIVES ON INTEGRATED MEMBRANE OPERATIONS FOR SUSTAINABLE
INDUSTRIAL GROWTH. K Drioli andM. Romano (Italy)
FOSTERING RESOURCE EFFICIENCY THROUGH NETWORKING AND CONVENIENT INFORMATION ACCESS
- GERMANY'S CLEARINGHOUSE COOPERATIVES ON CLEANER PRODUCTION IN THE WORLD WIDE WEB
(WWW). H. Pohle (Germany)
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CLEANER PRODUCTION STRATEGY AND TACTICS. W. Zadorshy (Ukraine)
CERAMIC MEMBRANES IN CLEAN PROCESSES IN RUSSIA. G. G. Kagramanov (Russia)
TOWARDS RESPONSIBLE INDUSTRIAL DISPOSAL IN SPAIN. /. Coca (Spain)
16:30 Break - Coffee/Tea
17:00 Poster and computer presentations
Posters:
CLEANER PRODUCTION OF FARMERS AND FOOD PRODUCERS IN THE CZECH REPUBLIC. A. Christianovd, F.
Bozek, J. Dvorak and A. Komar (Czech Republic)
ENVIRONMENTAL IMPACTS OF HC EMISSIONS IN LIFE CYCLE ANALYSIS OF GASOLINE BLENDING
OPTIONS. T. M. Mata, R. L. Smith, D. M. Young, and C. A. V. Costa (Portugal-USA)
CERAMIC MEMBRANES IN CLEAN PROCESSES IN RUSSIA. G. G. Kagramanov (Russia)
TOOLS AND METHODS FOR CLEAN TECHNOLOGIES. W. Zadorsky (Ukraine)
ENVIRONMENTAL BIOTECHNOLOGY IN THE QUESTOR CENTRE. /. Swindall (UK)
THE QUEENS UNIVERSITY IONIC LIQUID (QUILL) RESEARCH CENTRE. /. SwindaU (UK)
CATALYTIC TREATMENT OF GASEOUS EMISSIONS FROM COKE OVENS. L. S. Escandon, M. A. G. Hevia, J. R.
Paredes, P. Hurtado, S. Ordonez andF. V. Diez (Spain)
OPERATION OF AN EXPERIMENTAL PLANT FOR TREATMENT OF COKE OVEN WASTEWATER INSIDE A
SIDERULGICAL COMPANY. M. Diaz, A. Gutierrez and A. Rancano (Spain)
Computer demonstrations:
NATO CCMS CLEAN PRODUCTS AND PROCESSES WEB SITE U.S. EPA - LCACCESS. D. Murray (USA)
ENVIRONMENTALLY FRIENDLY TECHNOLOGIES DATABASE. W. Zadorsky (Ukraine)
ON-LINE VIRTUAL CLEANER TECHNOLOGY INCUBATOR. W. Zadorsky (Ukraine)
FOSTERING RESOURCE EFFICIENCY THROUGH NETWORKING AND CONVENIENT INFORMATION ACCESS
- GERMANY'S CLEARINGHOUSE COOPERATIVES ON CLEANER PRODUCTION IN THE WORLD WIDE WEB
(WWW). H. Pohle (Germany)
18:00 Sessions are over
20:30 Participants gather in the Hotel Ramiro I
21:00 Dinner at Auditorium Restaurant
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TUESDAY, MAY 8, 2001
08:15 Breakfast-Hotel Ramiro I
09:00 Presentation (30 min)
PROGRAMS OF THE U.S. NATIONAL SCIENCE FOUNDATION: AN OVERVIEW. T. W. Chapman (USA)
09:30 Tour de Table Presentations (15 min each)
CLEANER CHEMICAL PROCESSES BY USING PINCH ANALYSIS AND MATHEMATICAL PROGRAMMING. P.
Glavic (Slovenia)
POLLUTION PREVENTION IN ROMANIA - OPTIMISTIC PERSPECTIVE. K Harceag (Romania)
CLEANER TECHNOLOGIES AND INDUSTRIAL ECOLOGY. A. M. Fet (Norway)
THE ROLE OF ORGANISATIONAL FACTORS IN THE. IMPLEMENTATION OF CLEANER PRODUCTION
MEASURES. G. Zilahy (Hungary)
10:30 Break - Coffee/Tea
11:00 Pilot Project Updates (20 min each)
POLICY STATEMENT ON DEVELOPING GOODS AND SERVICES WHICH MEET PEOPLE'S NEEDS BUT
INVOLVE THE USE OF FEWER NATURAL RESOURCES IN MOLDOVA. S. Galitchi (Moldova)
NEW PROCESSES AND MATERIALS FOR ENVIRONMENTALLY BENIGN SEMICONDUCTOR
MANUFACTURING. F. Shadman (USA)
PILOT PROJECT ON EVALUATION OF CLEAN PRODUCTS AND PROCESSES IN MEMBER COUNTRIES. M.
Overcash (USA)
12:00 Tour de Table Presentations (15 min each)
(NATIONAL PROGRAM FOR CLEANER PRODUCTION. D. Sucharovova (Czech Republic)) NOT PRESENT
CYCLE OF REUSING INDUSTRIAL DUSTS FOR WASTEWATER TREATMENT AND CONSTRUCTION. A. Doniec
(Poland)
CASE STUDIES OF INDUSTRIAL WASTEWATER TREATMENT IN CONSTRUCTED WETLANDS. S. Martins Dias
(Portugal)
CLEANER PRODUCTION AND PRODUCTS IN LITHUANIA /. Staniskis (Lithuania)
13:00 Lunch at Auditorium Restaurant
14:30 Tour de Table Presentations (15 min each)
AGRIFOOD INDUSTRY IN BULGARIA. S. Tepavitcharova (Bulgaty)
CEVI, THE DANISH CENTRE FOR INDUSTRIAL WATER MANAGEMENT. H. Wenzel (Denmark)
THE STATE OF PLAY OF THE IPPC/96/61/EC DIRECTIVE: THE CASE OF FOOD INDUSTRIES WITH SPECIAL
REFERENCE TO GREECE. G. Gallios (Greece)
TITLE NOT AVAILABLE. C. Forgacs (Israel)
15:30 University-Industry Co-operation Presentations
QUESTOR/QUILL UPDATE. /. Swindall (UK)
16:00 Break - Coffee/Tea
16:30 University-Industry Co-operation Presentations
UNIVERSITY/INDUSTRY RELATIONS IN SPAIN. /. Coca (Spain)
17:00 Sessions are over. Departure for Visit (Bus)
17:30 Pre-Romanesque Asturian Art in Oviedo (approx. 1 hour) Return to the Hotel
20:30 Participants gather in the Hotel Ramiro I. Departure for Dinner (walking distance)
21:00 Dinner at Hotel Principado
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WEDNESDAY, MAY 9, 2001 - FIELD TRIP
08:00 Breakfast-Hotel Ramiro I
08:45 Boarding the bus
09:00 Visit to the Department of Chemical Engineering. University of Oviedo
10:00 Departure (Bus)
10:30 Visit to the Du Pont Company
12:30 Departure (Bus)
13:00 Lunch at La Mina Restaurant
15:00 Departure (Bus)
16:00 Visit to a cider production site: Villaviciosa
19:00 Return to Oviedo (approx. 30 min)
20:30 Participants gather in the Hotel Ramiro I. Departure for Dinner (Bus)
21:00 "Espicha" at "Llagar el Carbayon" Hotel La Grata
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THURSDAY, MAY 10, 2001
SPECIAL TOPIC DAY
ENVIRONMENTAL CHALLENGES IN THE PROCESS INDUSTRIES
08:15 Breakfast-Hotel Ramiro I
09:00 Welcome to the Special Topic Day. /. Coca andH. Sastre, Counselor of Environment of the Principality ofAsturias
09:10 Morning Conferences I (30 min each)
PRINCIPALITY OF ASTURIAS: ENVIRONMENTAL POLICY. T. Coca andH. Sastre, Government of the Principality
ofAsturias (Spain)
ADVANCES IN ENVIRONMENTAL ASPECTS OF DESALINATION: THE CANARY ISLANDS EXPERIENCE. M.
Hernandez-Juarez, Canary Islands Water Center (Spain)
ENVIROMENTAL PROGRESS IN DOW CHEMICAL IBERICA. /. Bessa, Responsible Care Leader, Dow Iberica, S.A.
(Spain)
10:40 Break - Coffee/Tea
11:00 Morning Conferences II (30 min each)
LIGNOSULPHONATES: ENVIRONMENTAL FRIENDLY PRODUCTS FROM A WASTE STREAM. M. Rodriguez,
Lignotech Iberica, S.A. (Spain)
HYDROGEN ECONOMY AND FUEL CELLS: ENERGY FOR THE FUTURE. M. A. Pena, Head of Department of
Structure and Reactivity, Institute of Catalysis and Petrochemistry, CSIC (Spain)
THE USE OF MEMBRANE TECHNOLOGY IN PULP AND PAPER INDUSTRY. D. Gomez, S. Luque, J. R Alvarez, J.
Coca Department of Chemical & Environmental Engineering. University of Oviedo (Spain)
13:00 Lunch at Auditorium Restaurant
14:30 Afternoon Conferences I (30 min each)
. ACTIVITIES AND INITIATIVES TO SUPPORT COMPANIES AND BUSINESS SECTORS TO IMPROVE THEIR
RELATIONSHIP WITH THE ENVIRONMENT. B. Gallego, Ministry of Environment of the Government of Catalonia
(Spain)
TREATMENT OF OIL-CONTAINING WASTEWATERS USING CLEAN TECHNOLOGIES. /. M. Benito, G. Rios, E.
Ortea, E. Fernandez, A. Cambiella, C. Pazos and J. Coca. Department of Chemical & Environmental Engineering.
University of Oviedo (Spain)
THE NEW LEGISLATION ON ENVIRONMENTAL QUALITY AND CLEAN PRODUCTION. /. Martinez Ministry of
Environment (Spain)
16:00 Break - Coffee/Tea
17:30 Afternoon Conferences II (30 min each)
NON-FERROUS METALLURGICAL WASTES: FUTURE REQUIREMENTS. /. M. Poncet, Asturiana de Zinc, S.A.
(Spain)
HOW TO MAKE CARBOCHEMISTRY COMPATIBLE WITH ENVIRONMENT. /. /. Fernandez and I. Trelles,
Department ofR&D, Industrial Quimica delNalon, S.A. (Spain)
TREATMENT OF PHENOLIC WASTEWATERS IN THE SALICYLIC ACID MANUFACTURING PROCESS. M. F.
Ortega, A. Cagigas, J. Alvarez, Quimica Farmaceutica Bayer, S.A. (Spain)
18:00 Sessions are over
20:30 Participants gather in the Hotel Ramiro I. Departure for Dinner (Bus)
21:00 Dinner at Latores Restaurant (Oviedo)
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FRIDAY, MAY 11, 2001
08:15 Breakfast-Hotel Ramiro I
09:00 New Pilot Projects
09:30 Discussion. Moderator: D. Murray, Pilot Study Co-Director
10:30 Break - Coffee/Tea
11:00 Future Directions for the Pilot Study. D. Murray, Pilot Study Co-Director
Topics and Focus for Next Meeting
Host Country and Dates for 2002 Meeting
12:30 Meeting Wrap Up. S. K. Sikdar, Pilot Study Director
13:00 Lunch at Auditorium Restaurant
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United States
Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
Official Business
Penalty for Private Use
$300
EPA/625/CR-02/003
PRESORTED STANDARD
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
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