Production-Integrated Environmental Protection and Waste Management in the Chemical Industry Book

1.	Introduction	1
2.	Production-Integrated Environmental Protection in the Chemical Industry	5
2.1.	Chemical Industry and Sustainable Development	5
2.2.	Formation of Residues in Chemical Processes	6
2.3.	Environmental Concepts in the Chemical Industry	9
2.3.1.	Review of the Environmental Concepts	9
2.3.2.	The Concept of Integrated Environmental Protection	10
2.3.3.	Environmental Protection in Research and Development	11
2.3.4.	Integrated and Additive Concepts of Environmental Protection	12
2.3.5.	Comparison of Integrated and Additive Environmental Protection	15
2.3.6.	Methods of material flow and cost management	21
2.4.	Limitations of Production-Integrated Environmental Protection	27
2.4.1.	Technical Limitations	28
2.4.2.	Economic Limitations	29
2.5.	Effect of Production-Integrated Environmental Protection	29
2.6.	Costs of Integrated Measures	31
3.	Examples of Production-Integrated Environmental Protection in the Chemical Industry	33
3.1.	Introduction	33
3.2.	Selected Examples	34
3.2.1.	Examples from Hoechst	34
3.2.1.1.	Recovery and Utilization of Residues in the Production of Viscose Staple Fiber	34
3.2.1.2.	Recovery of Methanol and Acetic Acid in Poly (Vinyl Alcohol) Production	40
3.2.1.3.	Acetylation without Contamination of Wastewater	40
3.2.1.4.	Reutilization Plant for Organohalogen Compounds	41
3.2.1.5.	Vacuum Technology for Closed Production Cycles	45
3.2.1.6.	Utilization of Exhaust Gases and Liquid Residues of Chlorination Processes for Production of Clean Hydrochloric Acid Hydrochloric Acid Hydrochloric Acid Hydroc	47
3.2.1.7.	Production of Neopentyl Glycol: Higher Yield by Internal Recycling	50
3.2.1.8.	Optimization of Ester Waxoil Production and Recovery of Auxiliary Products	51
3.2.1.9.	Biochemical Production of 7-Aminocephalosporanic Acid	53
3.2.1.10.	Production of	56
3.2.1.11.	Production of Theobromine	57
3.2.1.12.	Recovery of Organic Solvents	59
3.2.2.	Examples from Bayer	67
3.2.2.1.	Avoidance of Wastewater and Residues in the Production of H Acid (1-Amino-8-hydroxynaphthalene-3,6-disulfonic acid)	67
3.2.2.2.	High-Yield Production of Alkane-sulfonates by Means of Membrane Technology	71
3.2.2.3.	Selective Chlorination of Toluene in the	73
3.2.2.4.	Production of Naphthalenedisulfonic Acid with Closed Recycling of Auxiliaries	75
3.2.2.5.	Avoiding Residues in Dye Production by Using Membrane Processes	80
3.2.2.6.	Fuel Replacement in Sewage Sludge Combustion by Utilization of Chlorinated Hydrocarbon Side Products	81
3.2.3.	Examples from BASF	84
3.2.3.1.	Emission Reduction in Industrial Power Plants at Chemical Plant Sites by Means of Optimized Cogeneration	84
3.2.3.2.	Closed-Cycle Wittig Reaction	90
3.2.4.	Integrated Environmental Protection and Energy Saving in the Production of Vinyl Chloride (Example from Wacker Chemie)	93
3.2.5.	Examples from Huls	104
3.2.5.1.	Integrated Environmental Protection in Cumene Production	104
3.2.5.2.	Production of Acetylene by the Huls Plasma Arc Process	107
3.2.6.	Low-Residue Process for Titanium Dioxide Production (Example from Kronos International)	111
3.2.7.	Reduction of Waste Production and Energy Consumption in the Production of Fatty Acid Methyl Esters (Example from Henkel)	115
3.2.8.	Integrated Environmental Protection in the Production of Vitamins (Example from F. Hoffmann-La Roche)	122
3.2.9.	Production of Pure Naphthalene without Residues--Replacement of Chemical Purification by Optimized Multiple Crystallization (Example from	128
3.2.10.	Improvements in the Polypropylene Production Process (Example from Shell)	132
3.2.11.	The Zero-Residue Refinery Using the Shell Gasification Process (Shell-Lurgi Example)	135
3.2.12.	Neutral Salt Splitting with the Use of Hydrogen Depolarized Anodes (Hydrina Technology, Example from De Nora Permelec)	142
3.2.13.	Ultrapure Isopropanol Purification and Recycling System (Example from Mitsubishi Chemical)	151
3.2.14.	Examples from Boehringer Mannheim	156
3.2.14.1.	Biocatalytic Splitting of Penicillin	156
3.2.14.2.	Production of Diagnostic Reagents by Means of Genetic Engineering: Glucose-6-Phosphate Dehydrogenase and	158
4.	Waste Management in the Chemical Industry	163
4.1.	Introduction	163
4.2.	Chemical Industry Wastes	163
4.3.	Waste-Management Concepts	164
4.3.1.	Residues and Wastes from Production	164
4.3.2.	Production-Oriented Management	165
4.3.3.	Product-Oriented Management	166
4.4.	Disposal Measures	167
4.4.1.	Logistics	167
4.4.2.	Waste Combustion	168
4.4.3.	Landfill Disposal of Wastes	173
4.4.4.	Asbestos Disposal	174
4.5.	Utilization of Product Wastes	174
4.5.1.	Plastics Recycling	174
4.5.2.	Refrigerant Recycling	176
4.5.3.	Recycling of Used Packaging Materials	177
4.5.4.	Paint Recycling	178
4.6.	Results of Waste Management	178
5.	Summary and Outlook	183
6.	References	185
	Index	197